C15 and C18 On-Highway Engines Turbocharger - Remove and Install Caterpillar


Turbocharger - Remove and Install
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C15 and C18 On-Highway Engines [UENR3300]
AIR INLET AND EXHAUST SYSTEM
TURBOCHARGER GP
C15 and C18 On-Highway Engines Turbocharger - Remove and Install
1.1. Removal Procedure
2.1. Installation Procedure

Removal Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
−  Loctite C5-A Copper Anti-Seize Lubricant   − 


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.




    Illustration 1g01841534


    NOTICE

    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.


    ------ CAUTION! ------

    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 if the machine is equipped.

    Note: Ensure that all main surfaces are clean and free of debris.

  1. Loosen clamp assembly (1) and disconnect the hose that attaches to the intake side of the turbocharger (not shown).

  2. Remove clamp assemblies (2), (5), and (6).

  3. Disconnect both tube assemblies (3) and (4).


    Illustration 2g01841575

  4. Remove nuts (8) and discard the nuts. Use two people in order to remove turbocharger (7). The weight of turbocharger (7) is approximately 31 kg (70 lb).

  5. Remove the gasket from the exhaust manifold.


    Illustration 3g02216274

    Note: Clamp assemblies (9) are one time use parts. Discard the clamp assemblies whenever they are loosened.

  6. Loosen clamp assemblies (9) in order to separate the housings from the cartridge assembly. Discard clamp assemblies (9).

Installation Procedure


    NOTICE

    The alignment of the bellows is important. Improper alignment may lead to premature failure of the bellows. Misalignment can be identified by visually inspecting the convolutions for uniformity of compression.

    Inspect the bellows for damage prior to installation. If there is any damage to the convolutions, discard the bellows. Minor damage to the ends of the bellows may be repaired. However, if there is any difficulty in installation after the repair, discard the bellows.


  1. Install turbocharger (7) in the reverse order of removal.

    1. Tighten new clamp assemblies (9) to a torque of 13.6 ± 1.2 N·m (120 ± 11 lb in).

    2. Apply Tooling (A) to the threads of the studs and to the threads of nuts (8). Tighten nuts (8) to a torque of 70 ± 5 N·m (52 ± 4 lb ft).

    3. Tighten clamp assemblies (2) to a torque of 8.5 ± 2 N·m (75. ± 17 lb in).

    4. Tighten clamp assembly (6) to a torque of 12 ± 4 N·m (106 ± 35 lb in).

    5. Tighten clamp assembly (1) to a torque of 13.5 ± 1 N·m (119 ± 9 lb in).

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