C15 and C18 Engines for Caterpillar Built Machines Turbocharger - Remove and Install - High Pressure, For Series Turbocharger Applications Caterpillar

Removal Procedure

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Illustration 1	g02346356

1. Place Mark (X) at all four locations as shown. This action will aid in the installation of the lines group.

2. Loosen clamp assemblies (1) and (3) . Remove lines group (2) .

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Illustration 2	g02346357

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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.

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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 if the machine is equipped.

3. Remove both clamp assemblies (5) . Remove bellows (6) and position exhaust tube assemblies (4) and (7) aside. Discard clamp assemblies (5) and bellows (6) .

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Illustration 3	g02346358

4. Place Mark (Y) at all four locations as shown. This action will aid in the installation of the lines group.

5. Remove clamp assemblies (8) and (10) , and remove lines group (9) .

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Illustration 4	g02346359

6. Remove both clamp assemblies (12) . Remove bellows (13) and position tube assemblies (11) and (14) aside. Discard clamp assemblies (12) and bellows (13) .

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Illustration 5	g02346362

7. Place Mark (Y) at all four locations as shown. This action will aid in the installation of the lines group.

8. Loosen clamp assemblies (15) and (17) and discard the clamp assemblies. Remove lines group (16) .

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Illustration 6	g02346365

Note: Refer to Special Instruction, REHS1728, "Application Guideline for the Bellows" for additional information on handling the bellows if the machine is equipped.

9. Remove both clamp assemblies (19) . Remove bellows (20) and position elbow assemblies (18) and (21) aside. Discard clamp assemblies (19) and bellows (20) .

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Illustration 7	g02346366

10. Disconnect tube assembly (22) .

11. Disconnect tube assemblies (23) and (24) and position the tube assemblies out of the way.

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Illustration 8	g02346367

12. Attach a suitable lifting device to turbocharger (25) . The weight of turbocharger (25) is approximately 27 kg (60 lb). Remove nuts (26) and remove the turbocharger. Discard nuts (26) .

Installation Procedure

Note: Check all of the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.

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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 (25) in the reverse order.

   1. Apply Tooling (A) to the threads of the studs and to the threads of new nuts (26) . Tighten the new nuts (26) to a torque of 70 ± 5 N·m (52 ± 4 lb ft).
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   Illustration 9	g02346365

   2. Position new bellows (20) , new clamp assemblies (19) , elbow assembly (18) , and elbow assembly (21) . Tighten clamp assemblies (19) to a torque of 8.5 ± 1 N·m (75 ± 9 lb in).

   3. Tighten new clamp assemblies (15) and (17) to a torque of 8.5 ± 1 N·m (75 ± 9 lb in).
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   Illustration 10	g02346359

   4. Position new bellows (13) , new clamp assemblies (12) , elbow assembly (11) , and elbow assembly (14) . Tighten clamp assemblies (12) to a torque of 35 ± 2 N·m (26 ± 1 lb ft).

   5. Tighten new clamp assemblies (8) and (10) to a torque of 20 ± 2 N·m (15 ± 1 lb ft).
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   Illustration 11	g02346357

   6. Position new bellows (6) , new clamp assemblies (5) , elbow assembly (4) , and elbow assembly (7) . Tighten clamp assemblies (5) to a torque of 8.5 ± 1 N·m (75 ± 9 lb in). Ensure that the flow indicator on the bellows is in the position that is shown in the above illustration.

   7. Tighten new clamp assemblies (1) and (3) to a torque of 20 ± 2 N·m (15 ± 1 lb ft).