3406E TRUCK ENGINE Caterpillar


Turbocharger

Usage:

Remove and Install 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 the 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.


Typical Example

1. Remove tube assemblies (1) and (2) from the turbocharger cartridge assembly. Check the condition of the O-ring seals on tube assemblies (1) and (2). Use new parts for replacement if the O-ring seals are worn or damaged.

2. Attach a strap and hoist to turbocharger (3).

3. Remove four turbocharger to manifold bolts (4) and turbocharger (3). Turbocharger (3) weighs approximately 34 kg (75 lb).

NOTE: The following steps are for the installation of the turbocharger.


NOTICE

Reorient the turbocharger compressor housing, the turbine housing and the cartridge assembly as follows:


4. Loosen the V-band clamps only enough to allow the housing to rotate.

5. Put 5P-3931 Anti-Seize Compound on turbocharger to manifold bolts (4).

6. Position housings with air pipes, exhaust pipes, and oil lines so they are all aligned without binding. Install turbocharger to manifold bolts (4) loosely.


NOTICE

Do not tighten turbocharger to manifold bolts at this time.


7. Tighten turbine V-band clamp to a torque of 14 ± 3 N·m (10 ± 2 lb ft).

8. Tighten turbocharger to manifold bolts (4) to a torque of 55 ± 5 N·m (40 ± 4 lb ft).

9. Position the compressor housing so the air outlet is "zero" degrees from top vertical.

10. Position the compressor V-band clamp joint to 90 ± 10 degrees outboard from the bottom vertical.

11. Tighten the V-band clamp nuts on band clamps (3) to a torque of 14 ± 3 N·m (10 ± 2 lb ft). Use a soft hammer to lightly hit around the diameters of band clamps (3).

12. Install tube assemblies (1) and (2).

Disassemble and Assemble Turbocharger

Start By:

a. remove turbocharger

1. Position the turbocharger assembly on a bench. Disconnect support clamp and hose (1) from the wastegate assembly.

2. Loosen the band clamp nuts on band clamps (3).


NOTICE

Compressor housing (2) must go straight on and straight off turbocharger cartridge assembly (4) without tilting or the compressor blade tips or the compressor shaft can be bent or damaged.


3. Separate compressor housing (2) and turbine housing (5) from turbocharger cartridge assembly (4).


NOTICE

Do not attempt to disassemble the turbocharger cartridge assembly or the wastegate. Do not remove the compressor wheel. The turbocharger cartridge assembly and the wastegate are not "field serviceable," and should be replaced only as a unit.


4. Check the condition of all components. Use new parts to replace any worn or damaged components.

5. Assemble the turbocharger assembly in the reverse order of removal.

6. Tighten the V-band clamp nuts on band clamps (3) to a torque of 14 ± 3 N·m (10 ± 2 lb ft). Use a soft hammer to lightly hit around the diameters of band clamps (3).

7. Tighten the band clamp nuts on band clamps (3) again to a torque of 14 ± 3 N·m (10 ± 2 lb ft).

End By:

a. install turbocharger

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