Disassembly And Assembly Of The TPS 57 Turbocharger{1052} Caterpillar

Engine:

G3606B (S/N: 4ZS)

Introduction

This Special Instruction was written in order to provide instructions for the disassembly and assembly of the TPS 57 turbocharger. The entire instruction should be read and understood before any work is done on the engine.

Required Tools

• 138-7575 Link Brackets (2)

Disassembly

Put identification marks on all of the casings and housings in order to correctly align the turbocharger upon assembly.

1. Remove the turbocharger from the engine.

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Illustration 1	g00373373

2. Attach the 138-7575 Link Brackets (A), a lifting sling, and a suitable lifting device to the exhaust adapter (2) .

3. Remove the twelve bolts, nuts, and washers (1) .

4. Remove the exhaust adapter (2). The weight of the exhaust adapter is approximately 31 kg (68 lb).

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Illustration 2	g00373392

5. Remove the gasket (3) from the turbocharger.

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Illustration 3	g00373454

6. Loosen the V-band clamp (5) .

7. Attach the 138-7575 Link Bracket (A) and a suitable lifting device to the housing (4) at position (B) .

8. Remove the V-band clamp (5). Remove the housing (4) .

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Illustration 4	g00373492

9. Remove the O-ring seal (6) from the housing (4) .

   Note: Inspect the O-ring seal for damage. If necessary, replace the O-ring.

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Illustration 5	g00373532

10. Attach the 138-7575 Link Bracket (A) and a suitable lifting device to the compressor housing (7) .

11. Rotate the compressor housing (7) so that the flange is up.

12. Remove the V-band clamp (8). Remove the compressor housing (7). The weight of the compressor housing (7) is approximately 51 kg (112 lb).

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Illustration 6	g00373552

13. Remove the O-ring seal (10) from the cartridge assembly (9) .

    Note: Inspect the O-ring seal for damage. If necessary, replace the O-ring.

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Illustration 7	g00373572

14. Reposition the turbocharger so that the cartridge assembly (9) is up.

15. Remove the V-band clamp (11) .

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Illustration 8	g00373632

16. Install the two steel rods through the holes in the cartridge assembly (9). The rods should have a diameter of approximately 19 mm (0.75 inch) and a length of approximately 610 mm (24 inch).

17. Attach the lifting slings and a suitable lifting device to the steel rods.

18. Remove the cartridge assembly (9) from the turbine assembly (12). The weight of the cartridge assembly (9) is approximately 80 kg (176 lb).

Assembly

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Illustration 9	g00373632

1. Install two steel rods through the holes in the cartridge assembly (9). The rods should have a diameter of approximately 19 mm (0.75 inch) and a length of approximately 610 mm (24 inch). Attach lifting slings and a suitable lifting device to the steel rods.

   Note: Ensure that the identification marks on all casings and housings are aligned upon assembly.

2. Install the cartridge assembly (9) into the turbine assembly (12) .

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Illustration 10	g00373572

3. Install the V-band clamp (11). Tighten the V-band clamp (11) to a torque of 60 N·m (44 lb ft).

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Illustration 11	g00373552

4. Install the O-ring seal (10) into the groove in the cartridge assembly (9) .

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Illustration 12	g00373532

5. Install the 138-7575 Link Bracket (A) and a suitable lifting device to the compressor housing (7) .

6. Install the compressor housing (7). Tighten the V-band clamp (8) to a torque of 60 N·m (44 lb ft).

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Illustration 13	g00373492

7. Install the O-ring seal (6) into the groove in the housing (4) .

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Illustration 14	g00373454

8. Attach the 138-7575 Link Bracket (A) and a suitable lifting device to the housing (4) at position (B). Install the housing (4). Install the V-band clamp (5). Tighten the V-band clamp (5) to a torque of 60 N·m (44 lb ft).

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Illustration 15	g00373392

9. Install the gasket (3) .

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Illustration 16	g00373373

10. Attach the 138-7575 Link Brackets (A), a lifting sling, and a suitable lifting device to the exhaust adapter (2) .

11. Install the exhaust adapter (2). Install the twelve bolts, nuts, and washers (1). Tighten the bolts to a torque of 65 N·m (48 lb ft).

12. Install the turbocharger on the engine.