Removal Procedure
Start By:
- Remove the combustion body group. Refer to Disassembly and Assembly, "Combustion Body Group (ARD) - Remove".
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Sulfuric Acid Burn Hazard, may cause serious personal injury. The turbocharger may contain a small amount of sulfuric acid. The use of fuel with sulfur levels greater than 15 ppm may increase the amount of sulfuric acid formed. The sulfuric acid may spill from the CGI cooler during service of the engine and may travel to other downstream components. The sulfuric acid will burn the eyes, skin, and clothing on contact. Always wear the appropriate personal protective equipment (PPE) that is noted on a material safety data sheet (MSDS) for sulfuric acid. Always follow the directions for first aid that are noted on a material safety data sheet (MSDS) for sulfuric acid. |
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- Put identification marks on the bellows for alignment and orientation during installation of the bellows.
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
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Failure to follow established procedures can lead to damage of the parts. To avoid damage to the parts, always identify and mark the parts so that the parts can be installed in the same location. |
- Disconnect clamp (1) . Disconnect clamp (4) . Remove duct (2) and bellows (3) . Disconnect hose (5) .
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| Illustration 1 | g01400208 |
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The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions. |
Note: Refer to Special Instruction, REHS1728, "Application Guideline for the Bellows" for additional information on handling the bellows.
- Disconnect tube assembly (6) . Disconnect tube assembly (7) .
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| Illustration 2 | g01288057 |
- Disconnect tube assembly (8) . Remove nut (10) . Position tube assembly (8) out of the way. Disconnect tube assembly (13) . Disconnect harness assembly (14) . Position tube assembly (13) and harness assembly (14) out of the way. Disconnect clamp (9) . Disconnect clamp (12) .
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| Illustration 3 | g01288075 |
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The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions. |
Note: Refer to Special Instruction, REHS1728, "Application Guideline for the Bellows" for additional information on handling the bellows.
- Remove duct (11) and bellows (15) .
- Loosen clamp (16) and clamp (17) . Position hose (18) out of the way.
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| Illustration 4 | g01288078 |
- Attach a suitable lifting device onto turbocharger (19) . The weight of turbocharger (19) is approximately 34 kg (75 lb).
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| Illustration 5 | g01288085 |
- Remove bolts (20) .
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| Illustration 6 | g01400251 |
- Remove turbocharger (19) .