LIGHTING GP-BOOM 1485178 - Caterpillar

1. Remove bolt (1) and washer (2). 2. Loosen bolts (3), (4) and (6) to loosen tube (5). 3. Remove oil inlet and outlet lines (7) from the turbocharger. 4. Remove four bolts (8) and nuts. Remove turbocharger (9), gasket and the coupling.Install Turbocharger
1. Install new O-ring seals (2) and put clean engine oil on the O-ring seals. Be sure the seal rings are not damaged on coupling (1) and put the coupling in position. 2. Put the turbocharger in position with a new gasket (3).3. Put 5P3931 Anti-Seize Compound on the threads of the bolts and nuts that hold the turbocharger to the elbow. Tighten the nuts to a torque of 40 4 lb.ft. (55 5 N m). 4. Tighten bolts (4), (6) and (7) that hold elbow (5). 5. Install oil inlet and outlet lines (8) on the turbocharger. 6. Install washer (10) and bolt (9). a) install heat shield (marine only)b) install air cleanerDisassemble Turbochargers
start by:a) remove turbocharger 1. Put turbocharger in position on tool group (A). Put a mark on cover (1), cartridge (3) and housing (2) for correct alignment and installation at assembly.2. Remove twelve bolts (4) and six clamps. 3. Remove O-ring seal (5) from the cover. 4. Bend back locks (6) and remove bolts (7). Remove cartridge assembly (3) from the turbine housing. 5. Put the cartridge assembly (3) in position on tool (B).
When the nut is loosened, do not put a side force on the shaft.
6. Remove the nut that holds compressor wheel (8) in position.7. Put the cartridge assembly in position in a press. Remove compressor wheel and shaft from the cartridge. 8. Remove shroud (9) and ring from the shaft. Use the 5P6518 Reusability Fixture Group to check the shaft to make sure it is straight. Complete instructions and parts specifications are given in special instruction form SMHS6998. 9. Remove spacer (10) from the cartridge assembly. 10. Remove the two rings (11) from the spacer. 11. Bend back locks (14). Remove bolts (13) and plate assembly (12).12. Remove O-ring seal (15) from the plate. 13. Start from top and remove collar bearing, bearing and ring. Use tool (C) to remove snap ring. 14. Turn cartridge housing over. Start from top and use tool (C) to remove snap ring. Remove ring and bearing. Use tool (C) to remove snap ring. Assemble Turbochargers
1. Clean and inspect all parts. Make a replacement of the parts that are worn or damaged. See SPECIAL INSTRUCTION Form No. SMHS6854 for TURBOCHARGER RECONDITIONING. Also see GUIDELINE FOR REUSEABLE PARTS Form No. SEBF8018. 2. Install snap ring (1) in cartridge housing with tool (A). 3. Install bearing (2) in cartridge housing. 4. Install ring (3) in cartridge housing.5. Install snap ring (4) in cartridge housing with tool (A). 6. Turn the cartridge housing over. Install snap ring (5) in housing with tool (A). 7. Install ring (7) and bearing (6) in the cartridge housing. 8. Install thrust bearing (8) in the cartridge housing. Make