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C280-08 Tier 4 Engine Caterpillar


Turbocharger - Remove and Install

Usage:

C280-08 J4R

Removal Procedure

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Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
A  395-1590  Lifting Eye Assembly  2 
B  -  Never-Seez Marine Grade  1 

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NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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NOTICE

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, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.

Dispose of all fluids according to local regulations and mandates.

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    Illustration 1g03856524

  1. Remove bolts (1) and shield (2).
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    Illustration 2g03856526

  2. Remove bolts (3) and shield (4).
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    Illustration 3g03856537

  3. Remove bolts (5) and shield (6).
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    Illustration 4g03856543

  4. Remove bolts (7) and cover (8).
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    Illustration 5g03856546

  5. Remove bolts (9) and cover (10).
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    Illustration 6g03856553

  6. Remove bolts (11) and shield (12).
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    Illustration 7g03856555

  7. Disconnect spring latches (14) and remove cover (13).
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    Illustration 8g03856557

  8. Remove bolts (15) and bracket (16).
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    Illustration 9g03856559

  9. Remove bolts (17) and shield (18).
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    Illustration 10g03856562

  10. Remove bolts (19) and shield (20).
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    Illustration 11g03856564
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    Illustration 12g03856566

  11. Remove bolts (21) and (23) and shield (22).
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    Illustration 13g03856569
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    Illustration 14g03856571

  12. Remove bolts (24) and (25) and shield (26).
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    Illustration 15g03856575

  13. Remove bolts (27) and shield (28).
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    Illustration 16g03856579

  14. Remove bolts (29) and cover (30).
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    Illustration 17g03856581

  15. Remove bolts (31) and shield (32).
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    Illustration 18g03856582

  16. Remove bolts (33) and shield (34).
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    Illustration 19g03856589

  17. Remove bolts (35) and shield (36).
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    Illustration 20g03856587

  18. Remove bolts (37) and cover (38). Disconnect latches (39).
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    Illustration 21g03856610

  19. Remove bolts (40) and cover (41).
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    Illustration 22g03856593

  20. Remove bolts (43) and cover (42).
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    Illustration 23g03856622

  21. Remove bolts (44) and cover (45).
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    Illustration 24g03856633

  22. Remove bolts (47) and shield (46).
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    Illustration 25g03860579

  23. Remove bolts (48) from the bellows.
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    Illustration 26g03860580

  24. Remove bolts (49) and elbow and bellows assembly (50). Remove the gaskets.
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    Illustration 27g03860582

  25. Disconnect tube assembly (53). Remove bolts (51) and air inlet elbow (52).
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    Illustration 28g03860583

  26. Attach Tooling (A) and a suitable lifting device to turbocharger (54). The weight of turbocharger (54) is approximately 819 kg (1806 lb). Remove bolts (55) and remove turbocharger (54). Remove the O-ring seals from the oil return tube.
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    Illustration 29g03860584

  27. Disconnect latches (56). Remove bolts (58) and remove shield assembly (57).
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    Illustration 30g03860586

  28. Remove bolts (60) and shield assembly (59).
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    Illustration 31g03860588
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    Illustration 32g03860589

  29. Remove bolts (61) and (62) and remove shield assemblies (63).

Installation Procedure

  1. Apply Tooling (B) to all of the hardware for the exhaust shielding and the turbo shielding prior to installation.
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    Illustration 33g03860589
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    Illustration 34g03860588

  2. Position shield assemblies (63) and install bolts (62) and (61).
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    Illustration 35g03860586

  3. Install shield assembly (59) and install bolts (60).
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    Illustration 36g03860584

  4. Install shield assembly (57) and install bolts (58). Connect latches (56).
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    Illustration 37g03860583

  5. Attach Tooling (A) and a suitable lifting device onto turbocharger (54). The weight of turbocharger (54) is approximately 819 kg (1806 lb).

  6. Install new O-ring seals on the oil return tube. Install turbocharger (54) onto the mounting bracket and install bolts (55).
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    Illustration 38g03860582

  7. Install air inlet elbow (52) and install bolts (51). Connect tube assembly (53).
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    Illustration 39g03860580

  8. Position elbow and bellows assembly (50) and install bolts (49). Tighten bolts (49) that attach the compressor housing to the bellows to a torque of 120 ± 20 N·m (89 ± 15 lb ft). Tighten bolts (49) that attach the elbow to the air inlet shutoff to a torque of 47 ± 9 N·m (35 ± 7 lb ft).
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    Illustration 40g03860579

  9. Apply Tooling (B) to bolts (48). Install bolts (48) and tighten to a torque of 135 ± 20 N·m (100 ± 15 lb ft).
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    Illustration 41g03856633

  10. Install shield (46) and bolts (47).
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    Illustration 42g03856622
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    Illustration 43g03856593
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    Illustration 44g03856610

  11. Install covers (45), (42), (41), and bolts (44), (43), and (40).
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    Illustration 45g03856587

  12. Install cover (38). Connect latches (39) and install bolts (37).
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    Illustration 46g03856589

  13. Install cover (36) and bolts (35).
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    Illustration 47g03856582

  14. Install cover (34) and bolts (33).
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    Illustration 48g03856581

  15. Install shield (32) and bolts (31).
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    Illustration 49g03856579

  16. Install cover (30) and bolts (29).
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    Illustration 50g03856575

  17. Install shield (28) and bolts (27).
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    Illustration 51g03856571
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    Illustration 52g03856569

  18. Install shield (26), bolts (25), and (24).
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    Illustration 53g03856566
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    Illustration 54g03856564

  19. Install shield (22), bolts (23), and (21).
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    Illustration 55g03856562

  20. Install shield (20) and bolts (19).
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    Illustration 56g03856559

  21. Install shield (18) and bolts (17).
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    Illustration 57g03856557

  22. Install bracket (16) and bolts (15).
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    Illustration 58g03856555

  23. Install cover (13) and connect spring latches (14).
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    Illustration 59g03856553

  24. Install shield (12) and bolts (11).
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    Illustration 60g03856546
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    Illustration 61g03856543

  25. Install covers (10) and (8). Install bolts (9) and (7).
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    Illustration 62g03856537

  26. Install shield (6) and bolts (5).
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    Illustration 63g03856526

  27. Install shield (4) and bolts (3).
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    Illustration 64g03856524

  28. Install shield (2) and bolts (1).

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