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. Drain the coolant from the cooling system into a suitable container for storage or disposal.
2. Disconnect the turbocharger from the exhaust system.
3. Remove four bolts (1) and remove elbow (2).
4. Disconnect hose (3) from the turbocharger. Cap and plug all openings immediately.
5. Disconnect hose (4), tubes (6) and line (5) from the turbocharger. Remove two bolts (7) from the oil return tube.
6. Loosen the hose clamps (10) and disconnect the air inlet hose. Install lifting sling (9), remove four bolts (11) and remove turbocharger (8). The weight of the turbocharger is approximately 36 kg (80 lb).
NOTE: The following steps are for installation of the turbocharger.
7. Make sure the studs are tightened in the exhaust manifold assembly to a torque of 25 ± 4 N·m (20 ± 3 lb ft).
8. Install the gasket on the exhaust manifold assembly.
9. Fasten a suitable lifting device and put the turbocharger in position. Put 5P-3931 Anti-Seize Compoundon the threads of the studs and nuts (11). Install the nuts and tighten them to a torque of 54 ± 5.5 N·m (40 ± 4.00 lb ft).
10. If necessary, make a replacement of the O-ring seals on elbow (2) and put clean engine oil on them.
NOTE: Put 4C-5598 Anti-Seize Compound on the threads of the bolts that hold elbow (2) to the inlet manifold. Install elbow (2).
11. Install the air inlet hose and tighten clamps (10). Position oil return tube and install bolts (7). Connect two tubes (6) and line (5). Install two hoses (3) and (4).
NOTE: For more detailed information regarding the turbocharger, see the topic "Turbocharger" in the Specifications Manual.
12. Fill the cooling system with coolant to the correct level. Refer to the Operation & Maintenance Manual for this procedure.
Disassemble & Assemble 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. Install turbocharger in Tool Group (A). Put marks on the three housings of the turbocharger for correct installation and alignment at assembly. Loosen "V" clamp (2) and remove compressor housing (1).
2. Loosen "V" clamp (3). Remove cartridge housing (4) from turbine housing (5).
3. Put the cartridge assembly in Tool (B) as shown.
| NOTICE |
|---|
do not put a side force on the shaft. |
4. Use Tool (C) and remove the nut that holds compressor wheel (6). Remove compressor wheel (6).
5. Remove turbine shaft (7) from the cartridge housing.
6. Remove seal ring (9) and shroud (8) from turbine shaft (7).
7. Use Tool (D) and remove ring (11) that holds insert (10) in the cartridge housing.
8. Remove insert (10) with Tooling (E).
9. Remove O-ring seal (13) and sleeve (12) from insert (10). Remove the seal ring from sleeve (12).
10. Remove deflector (14) and ring (15).
11. Remove bearing (16), sleeve (17) and ring (18).
NOTE: The dye marks put on bearings (19) and (20) are used for identification of the bearings when they are installed.
12. Use Tool (F) and remove the ring that holds bearing (19) in position. Remove bearing (19) and put a long dye mark on the top face of the bearing.
13. Turn the cartridge assembly over. Use Tool (F) and remove the ring that holds bearing (20) in position. Remove bearing (20) from the cartridge housing. Put a short dye mark on the top face of bearing (20).
14. If necessary, remove the two rings that hold the bearings in position from the cartridge housing with Tool (F).
15. Check all parts of the turbocharger for damage. If the parts have damage, use new parts for replacement. See Special Instruction, SMHS6854 for Turbocharger Reconditioning. Also see Guideline For Reusable Parts, SEBF8018.
NOTE: The following steps are for assembly of the turbocharger.
16. Make sure all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material.
17. Put clean engine oil on all parts of the cartridge assembly.
NOTE: Install the rings that hold the bearings in position with the round edges of the rings toward the bearings.
18. Make a replacement of the two inside rings that hold the bearings in position in the cartridge housing if necessary.
19. Install bearing (20) with the short dye mark up. Use Tool (F) to install the ring to hold the bearing in position.
20. Turn the cartridge assembly over and install bearing (19) with the long dye mark up. Use Tool (F) and install the ring to hold the bearing in position.
| NOTICE |
|---|
Make sure the oil hole in bearing (16) is open and clean to prevent a bearing failure. |
21. Install ring (18), sleeve (17) and bearing (16).
22. Install ring (15) and deflector (14).
23. Install O-ring seal (13) around insert (10).
24. Install the seal ring on sleeve (12).
25. Install sleeve (12) in insert (10) from the bottom side.
26. Install insert (10) in the cartridge housing. Use Tool (D) and install ring (11) to hold the insert in position.
27. Put turbine shaft (7) in position in Tool (B). Put Loctite LB 8632 Silicone Lubricant (North America), Loctite LB 8104 Silicone Lubricant (EAME), Loctite LB 8801 Silicone Lubricant (Asia Pacific Division), or Loctite LB Superlube (South America)in the groove for seal ring (9). Make sure the grease fills the groove approximately one half or more of the groove depth for the complete circumference of the groove to help make a carbon dam under the seal ring. Install seal ring (9) and shroud (8) on turbine shaft (7).
28. Install the cartridge housing on turbine shaft (7). Make sure seal ring (9) is fitted correctly in the cartridge housing.
| NOTICE |
|---|
Do not put a side force on turbine shaft (7) when the nut is tightened. |
29. Install compressor wheel (6) on the turbine shaft. Put clean engine oil on the threads of the turbine shaft. Install the nut that holds the compressor wheel on the turbine shaft. Use a torque wrench and a universal socket of the correct size and tighten the nut to a torque of 43 ± 3 N·m (32 ± 2 lb ft).
30. Make sure the compressor wheel is clean and dry.
31. Put the cartridge housing in a vise as shown. Check the shaft end play with Tool (G). The end play must be 0.114 ± 0.038 mm (.0045 ± .0015 in)(new), 0.20 mm (.008 in)maximum permissible (worn). If the shaft end play is not the correct dimension, the inside parts of the cartridge housing must be checked for too much wear.
32. Install the turbine housing on Tool Group (A). Put the cartridge assembly in position in the turbine housing. Make sure the marks on the housings are in alignment with each other. Put 5P-3931 Anti-Seize Compoundon the threads of the "V" clamp that holds the cartridge assembly to the turbine housing. Install the "V" clamp and tighten the bolt to a torque of 13.6 ± 1.1 N·m (120.00 ± 10.00 lb in).
33. Install the compressor housing to the cartridge assembly. Make sure the marks on the housings are in alignment with each other. Install the "V" clamp that holds the compressor housing to the cartridge housing and tighten the bolt to a torque of 13.6 ± 1.1 N·m (120 ± 10 lb in).
NOTE: For more detailed information regarding the turbocharger, see the topic "Turbocharger" in the Specifications Manual.
End By:
a. install turbocharger