TURBOCHARGER GP 1W1595 - Caterpillar

This is a 5.4-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Refer to the Service Manual as necessary.
Step1: Park the machine in a flat site & stop the engine.
Step2: Remove the pertinent covers for replacing the 2760939/2760940 Tube As.
First remove the 2759770 Cover As. Remove the 1989707 & 8T6412 Screws (THD M6) each are 3, total are 6 screws. (See Image1.2.1).
Second: Remove the 277-6743 Cover. It will be necessary to loosen the 8t4908/">8t-4908 Bolts (M8) Total 7 Bolts (See Image1.2.1).
Third: Remove the top Guard as-condenser (M12 bolt 3 pieces, M10 bolt 4 pieces) & the RH bracket as-lamp (M10 bolts 4 pieces).
Image1.2.1
Step3:
First: Replace the worn 2760939 Tube As. Tighten the upper connector end to a torque of 49+12/-1N.m. Tighten the lower connector end to a torque of 27+/-4N.m. Replace the worn 2760940 Tube As. Tighten the upper connector end to a torque of 49+12/-1N.m. Tighten the lower connector end to a torque of 14+/-4N.m (See Image1.31&1.32).
Second: Replace the lowest 4K-8302 Clip (See Image1.3.3) with the 9X-8606 Clip. Tighten the 7X-2548 Bolts to a torque of 100+/-20N.m.
Image1.3.1
Image1.3.2
Image1.3.3
Step4: Rework the 2776743 Cover.
First: Scribe the benchmark line as the cut line on the just removed 2776743 Cover according to the notch size shown in the image. (See Image 1.4.1 and 1.4.2)
Second: Flame cut the cover to the benchmark lines (See Image1.4.3).
Third: Deburr for the cutting edge with a grinding tool.
Fourth: Paint the cut notch Caterpillar Yellow(See Image1.4.4).
Image1.4.1
Image1.4.2
Image1.4.3
Image1.4.4
Step5: Reinstall the 2759770/2776743 Covers and the Guard As and RH lamp.
First: Install the 2759770 Cover. Tightening the side 3 screws first could be easier. (see Image1.5.1) Tighten the 8T6412 and 1989707 Bolts to a torque of 12+/-3N.m.
SECOND: Install the reworked 277-6743 Cover. Tighten the 8t4908
Bolts (M8) to a torque of 28+/-7N.m (see Image1.5.2).
Image1.5.1
Image1.5.2
Step5: Refill the refrigerant 134A as necessary. Make sure the air-conditioner is working properly before returning the machine to service.