- Caterpillar Products
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Introduction
Revision | Summary of Changes in SEBF8018 |
---|---|
34 | Added new Serial Number prefixes |
33 | Added part number for glass beads. |
32 | Updated and added multiple turbo cartridge specifications. |
31 | Combined information from SEBF2101, SEBF2102, SEBF2103, SEBF2104, SEBF2163, SEBF8018, SEBF8071, SEBF8092, SEBF8403, SEBF8966, SEBF9085, SEBF9110, SEBF9202, SEBF9207, SEBF9319, and repaired 95 pixelated illustrations. |
© 2019 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.
Information contained in this document is considered Caterpillar: Confidential Yellow.
This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.
For technical questions when using this document, work with your Dealer Technical Communicator (TC).
To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.
Important Safety Information
Illustration 1 | g02139237 |
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. |
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the safety alert symbol which is followed by a signal word such as danger, warning, or caution. The "WARNING" safety alert symbol is shown below.
Illustration 2 | g00008666 |
This safety alert symbol means:
Pay attention!
Become alert!
Your safety is involved.
The message that appears under the safety alert symbol explains the hazard.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.
The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.
Summary
This guideline can be used in the selection of turbocharger parts to be used again during the reconditioning operation. A visual comparison can be made between the turbocharger components removed during disassembly and the illustrations in this guideline to find out if turbocharger components can be used again. Many times, the use of new turbocharger components is not necessary. Installation of used turbocharger components during turbocharger reconditioning will give acceptable service life and a large reduction in the cost of a rebuilt turbocharger. During the reconditioning of the turbocharger, correct any conditions that caused the original failure before the turbocharger is put back into operation.
Note: Do not reuse aluminum compressor wheels in certain high cyclical and high load applications.
Note: Use 6V-2055 Grease in the seal ring grooves during all turbocharger reconditioning.
A turbocharger component that meets the specifications can be expected to give normal performance in the same application. This normal performance will last until the next overhaul.
Note: The specifications that follow are for components that have standard size. Some diameters of bearing journals and some bearing bore diameters can be different if a repair has been previously made.
The given specifications for the seal ring groove for some current turbochargers may be exceeded in many applications up to the limits that existed for earlier units. Refer to this guideline for specifications.
Service Advisories, Service Letters, and Technical Information Bulletins
NOTICE |
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The most recent Service Advisories and Service Letters that are related to this component should be reviewed before beginning work. Often Service Advisories, Service Letters, and Technical Information Bulletins contain upgrades in repair procedures, parts, and safety information which pertain to the components being repaired. |
Canceled Part Numbers and Replaced Part Numbers
This document may include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.
References
References | |
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Media Number | Publication Type & Title |
Channel1 | "Why Reuse and Salvage Parts" |
https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z | |
SEBF9238 | Reuse and Salvage Guidelines, "Fundamentals of Arc Spray for Reconditioning Components" |
SEBF9240 | Reuse and Salvage Guidelines, "Fundamentals of Flame Spray for Reconditioning Components" |
SEHS9031 | Special Instructions , "Storage Procedure for Caterpillar Products" |
SMHS6998 | Special Instructions"Instructions For The Use Of 5P-6518 Dial Indicator Fixture Group - Parts Reusability" |
Tooling and Equipment
NOTICE |
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Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components. To avoid component damage, follow the recommended procedure using the recommended tools. |
Required Tooling and Equipment | |
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Part Number | Description |
Retaining Ring Pliers | |
Gauge Group | |
Feeler Gauge | |
Dial Indicator | |
Penetrant Oil | |
Flapper Wheel | |
Flashlight | |
Grooved Pin | |
Caliper | |
Seal Pick | |
Dial Bore Gauge Group | |
Steel Ruler | |
Dial Indicator Fixture | |
Seal Pick | |
Adapter | |
Grease | |
Microscope | |
Indicator Contact Point | |
Contact Point | |
Microlite | |
Hammer | |
Feeler Gauge | |
Eye Loupe | |
Dial Indicator Group | |
Dial Indicator Group | |
Surface Reconditioning Pad | |
Thread Lock Compound | |
Fixture | |
Indicator Contact Point | |
Glass Beads | |
Inspection Mirror | |
Clamp | |
Shop Towels | |
Cleaner | |
Cut Off Wheel | |
Wastegate Setting Kit | |
Wheel Grinder | |
Pocket Microscope
40x |
|
Emery Polishing Paper | |
Paper Towel | |
Hose | |
Digital Caliper8s- | |
Micrometer Extensions, Internal |
|
Straight Edge | |
Digital Caliper
|
|
Micrometer, External |
|
17 mm Sideview Camera Borescope Probe | |
5.5 mm HD Camera Borescope Probe | |
Video Borescope - Wired Tool Group | |
Video Borescope - Wireless Tool Group | |
or |
Micrometer, Inside
2.00 - 12.00 inch |
Micrometer, Inside
50 - 300 mm |
|
Micrometer, Outside
0.00 - 4.00 inch |
|
Micrometer, Outside
2.00 - 6.00 inch |
|
Micrometer, Outside
|
|
Micrometer, Outside
|
|
or |
Micrometer, Inside
|
Micrometer, Inside
|
|
Pin Holder | |
Pin |
|
Pin |
|
Pin |
|
Pin |
|
Pin |
|
Pin |
|
Pin |
|
Pin |
|
7447 | 3M Type A Scotch-Brite Very Fine General Purpose Pad. |
Service Stand | |
Magnus Heavy-Duty Carbon Solvent |
Replacement Parts
Consult the applicable Parts Identification manual for your engine.
When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death. |
Measurement Techniques
NOTICE |
---|
Precise measurements shall be made when the component and measurement equipment are at |
Service Level of the Turbocharger
The service level of the turbocharger determines the components of the turbocharger that should be disassembled, the reusability of the individual parts, and the components that should be disassembled. If the turbocharger cartridge is the lowest level of service that is available, then the cartridge assembly should not be disassembled. This guideline does not list specifications for reusability for parts that are non-serviceable.
Turbo Rebuild Decision Matrix
This chart will help the dealer decide if rebuilding the turbocharger is going to be the correct method of repair. Repair is dependent upon the condition of the turbocharger upon arrival to the dealership. Following the chart will aid in offering the lowest cost option for rebuilds.
Illustration 3 | g06300092 |
Disassembling the Turbocharger
The procedures that are shown are the basic procedures for turbochargers. Due to the various turbocharger types, the actual parts in your turbocharger may differ slightly from the procedures that are shown. The procedures contain the basic principles of servicing a turbocharger and should serve as a guide when you are performing work on your turbocharger.
Note: The following turbochargers are not recommended to be rebuilt. These turbochargers have aluminum compressor wheels that may not live a full second life.
- Loosen the nuts and remove the two clamps that hold the compressor housing and the turbine housing on to the cartridge group. Some turbochargers are held together using bolts.
Note: A socket will not fit onto the bolt that is located under the oil line port due to limited space. If the bolt cannot be removed with a standard wrench, then chisel off the bolt. Refer to Illustration 6. The remainder of the bolt will have to be drilled out and the turbine housing retapped.
Show/hide tableIllustration 7 g06300980 Show/hide tableIllustration 8 g06300984 - Separate the compressor housing and the turbine housing from the cartridge group. The housings may be difficult to remove from the cartridge group. A brass drift and a hammer may be used to separate the housings from the cartridge group. Be cautious of damaging the turbine wheel and the compressor wheel.
Show/hide table
Illustration 9 g06300985 Show/hide tableIllustration 10 g03677879 Boreless Compressor Wheel with Internal Threads Show/hide tableIllustration 11 g06301001 - Remove the compressor wheel from the turbine shaft. Place the end of the turbine shaft into a vise and clamp onto the flat nut part of the turbine wheel. Remove the nut from the compressor wheel.
Turbochargers be it threaded, or boreless, the compressor wheels can be right or left-hand thread. Refer to Illustration 11.The end of the turbine shaft can also be placed into a vise and a pipe wrench used to remove the compressor wheel. Place tape around the end of the boreless compressor wheel to avoid damaging the wheel, as shown in Illustration 11
Show/hide tableIllustration 12 g06301006 - Remove the compressor wheel. The turbine shaft may need pressed from the compressor wheel, as shown.
Show/hide table
Illustration 13 g06301011 - Remove the seal rings from the turbine shaft.
Show/hide table
Illustration 14 g06301015 A backing plate that has been removed to expose thrust bearing and thrust washer Show/hide tableIllustration 15 g06301018 A turbocharger with the thrust washer and spacer removed
The seals for the compressor wheel are found on the spacerShow/hide tableIllustration 16 g06301020 This thrust bearing was located under the thrust washer and spacer - Some turbochargers have removable backplates that are removed by taking out bolts. Other turbochargers have removable backplates inserts that can be removed by removing the large retaining ring. The specific disassembly procedure that should be used to remove the thrust bearings and washers will depend upon the turbocharger that is being serviced. Some turbochargers have the thrust bearings and washers located under the backing plate. Some turbochargers have the thrust bearing and washer held in by large retaining rings and spacers.
Various spacers or washers can be used in the different turbochargers. A good practice is to record the location of the internal parts for reassembly.
Show/hide tableIllustration 17 g03675247 Removing the retaining ring using tooling 1U-5429 Retaining Ring Pliers (A). - The bearings can be removed after the various spacers, thrust washers, and the thrust bearing has been removed. Use Tooling (A) to remove retaining ring.
Show/hide table
Illustration 18 g06301021 Removing the bearing Show/hide tableIllustration 19 g06301024 Removing the washer - Remove the bearing and remove the washer that is located under the bearing.
- Repeat the previous two steps for the other bearing and washer.
Illustration 4 | g06300967 |
Turbocharger using clamps |
Illustration 5 | g06300969 |
Turbocharger using bolts |
Illustration 6 | g06300973 |
Cleaning Procedures
Illustration 20 | g06301026 |
Illustration 21 | g06301031 |
General
Improper care of parts during Disassembly and Assembly can cause a future failure of the turbocharger. Inspect the parts for defects to be sure that the parts can be used again. Use Magnus 763 N/F or a similar heavy-duty carbon solvent to loosen the carbon from the parts. For the best results, use a small closed tank for cleaning with the solvent. Make sure that the tank is agitated. After the carbon is loosened, use a hard bristle brush and remove all dirt particles. Clean all drilled passages with air under pressure.
NOTICE |
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Do not use caustic solutions, wire brushes, or wire wheels to remove carbon deposits from any turbocharger part. |
Any media blasting or bead blasting will VOID the REMAN Core Acceptance Criteria.
Removal of carbon deposits on some parts is difficult with solvent. Those parts can be cleaned with 9U-5271 Glass Beads. Use glass beads (size 10) that are
Note: There must be no aluminum oxide in the glass beads.
Some turbocharger parts must be polished with 266-3452 Emery Polishing Paper. Turbocharger parts that are cleaned with glass beads or polished with emery polishing paper must be cleaned in a solvent before reassembly. Put oil on cleaned parts to prevent corrosion.
Turbine Wheels and Shaft Assemblies
Illustration 22 | g06301035 |
Masking tape is used on the shaft and the bearing journals for protection from glass beads. |
Illustration 23 | g03703608 |
Masking tape is used on the shaft and the bearing journals for protection from glass beads. The seal ring area has been protected with an o-ring that fits the profile tightly. |
Illustration 24 | g03677509 |
Lightly bead blasting the turbine wheel to clean it is acceptable. |
Note: Do not allow the glass beads to hit the bearing journals, sealing surfaces or the threads on the shaft.
The carbon deposits must be removed from the seal ring grooves before the side clearance of the seal ring can be checked. Remove the carbon deposits with a hard bristle brush, a piece of the metal oil seal ring, or glass beads. After the carbon is removed from the seal ring grooves, lightly polish the side walls of the groove with 266-3452 Emery Polishing Paper.
Illustration 25 | g01410109 |
Cleaned turbine wheel |
Lacquer and carbon deposits that cannot be removed from the shaft with a heavy-duty carbon solvent and bristle brush can be removed with a Scotch-Brite fine general-purpose pad. Before the Scotch-Brite pad is used, put a clean, lightweight oil on the surface of the shaft. For best results with the Scotch-Brite pad, turn the wheel and shaft assembly in a lathe.
After the wheel and shaft assembly is cleaned, dry thoroughly with clean moisture free air. Put lightweight oil on the bearing journals and seal surfaces to prevent rust and corrosion.
Compressor Wheels
Illustration 26 | g01410114 |
Compressor wheel that was cleaned with glass beads |
NOTICE |
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Do not use glass beads on the compressor wheel bore or the mounting faces around the bore. Use tape or plugs to protect this area during glass beading. Thoroughly wash the compressor wheel in solvent after glass beading. |
Illustration 27 | g03677515 |
Using fine grit sandpaper for cleaning small burrs on the compressor wheel |
Center Housing
Illustration 28 | g01410119 |
If the glass beads are used to clean the center housings, use plugs that extend into the area of the bore so the plugs are over the complete length of the bearing bore. |
To remove some of the carbon deposits on the inside of the center housing, use glass beads through the oil return hole at the bottom of the center housing.
Cleaning carbon deposits from the center housing can be accomplished with solvent and scraping. No abrasive media should be used inside the center housing as it can cause contamination.
Illustration 29 | g01410120 |
Remove carbon deposits from the draining cavity with a carbon scraper. The carbon scraper can be made from |
NOTICE |
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Never assemble a turbocharger before the center housing is thoroughly cleaned with a heavy-duty carbon solvent. |
Illustration 30 | g06301042 |
Carbon Scraper | |
---|---|
Callout | Dimension |
A | |
B | |
C | |
D | |
E | |
The carbon scraper should be made from
Compressor and Turbine Housings
Illustration 31 | g06301048 |
The critical areas of the compressor housing and the turbine housing are the mounting flanges where the cartridge is attached to the housings. All foreign material should be removed from these areas, as indicated in Illustration 31.
After cleaning, use air under pressure to remove foreign material from the inside of the housings.
Turbine Wheel and Shaft Assembly
Illustration 32 | g01410122 |
(1) Blade
(2) Seal ring groove (3) Threaded area (4) Bearing journals (5) Hub area |
Turbine wheel and shaft assemblies with cracks in the blades or broken blades cannot be used again.
Turbine wheel and shaft assemblies can be used again if the blades are slightly bent. Turbine wheel and shaft assemblies with severely bent blades cannot be used again. Make sure that the bent blades do not have any cracks.
Note: Do not straighten bent blades.
Illustration 33 | g01410123 |
Turbine wheel has cracks in one blade and one broken blade. |
Do not use the part again.
Illustration 34 | g01410126 |
The turbine wheel has one slightly bent blade and no cracks. This blade can be clipped off but the turbine wheel & shaft assembly must be rebalanced. |
Use the part again.
Illustration 35 | g01410131 |
Turbine wheel has severely bent blades. |
Do not use the part again.
Illustration 36 | g01410132 |
The turbine wheel has a large amount of damage from foreign material. |
Do not use the part again.
Illustration 37 | g01410133 |
The turbine wheel has a small nick. The turbine wheel can be used again after the burrs are removed. Use a small file or an emery cloth that is medium grit to remove the burrs. |
Use the part again.
Illustration 38 | g01410134 |
Turbine blades show light damage from rubbing 360° around the turbine wheel. |
Use the part again.
Illustration 39 | g01410135 |
Turbine blades show light damage from rubbing 360° around the turbine wheel. |
Use the part again.
Illustration 40 | g01410136 |
Turbine blades show heavy rubbing. |
Do not use the part again.
Illustration 41 | g01410138 |
Turbine wheel shows heavy rubbing on the back face. |
Do not use the part again.
Illustration 42 | g06301056 |
The seal ring groove can sometimes be worn past the minimum specifications. The hub for the seal ring groove can be machined down and a sleeve (A) can then be pressed onto the shaft. The new seal ring groove can then be machined into the sleeve.
The carbon deposits must be removed before the grooves are checked. Refer to "Cleaning Procedures" for removal of the carbon deposits.
Use the procedure that follows to find the width of the seal ring grooves.
- Use a micrometer to measure the width of a new oil seal ring. Record this dimension.
- Install the oil seal ring in the groove of the oil seal. Measure the clearance between the seal ring and the sidewall of the groove with a feeler gauge.
- Add this dimension to the dimension for the width of the seal ring. This dimension will be the width of the seal ring groove.
If the width of the seal ring groove is more than the dimension given under the maximum width of the seal ring groove. then the turbine wheel and shaft assembly cannot be used again.
Illustration 43 | g01410139 |
The seal ring groove has a wear step in the outboard groove. |
Do not use the part again.
Some wheel and shaft assemblies have two seal ring grooves. The wheel and shaft assemblies that have two seal ring grooves can be used again if the wear of the outboard groove next to turbine wheel is within the specifications of wear. The wheel and shaft assemblies with two seal ring grooves can be used again if the inboard groove contains wear. Use both oil seal rings on these wheel and shaft assemblies.
If the wear of the outboard groove is not within the specifications of wear, then the wheel and shaft assembly cannot be used again.
Note: Always, use 6V-2055 Grease in the seal ring grooves before the seal rings are installed. This grease helps the seal rings to prevent leakage when the turbocharger is first put into operation.
Illustration 44 | g06301135 |
The inboard groove has wear. The outboard groove width is within the specifications of wear. (6) Outboard groove (7) Turbine wheel |
Use the part again.
Illustration 45 | g06301138 |
There is too much wear in both of the seal ring grooves. (6) Outboard groove (7) Turbine wheel |
Do not use the part again.
Illustration 46 | g01410144 |
Wheel and shaft assembly has damage to the seal ring groove. If the wheel and shaft assembly has two seal ring grooves, then both grooves must be free of damage to be used again. |
Do not use the part again.
Illustration 47 | g01410145 |
Wheel and shaft assembly shows erosion in the hub area of the shaft. |
Use the part again.
Illustration 48 | g01410146 |
The bearing journal has deep scratches and excessive wear. |
Do not use the part again.
Illustration 49 | g01410147 |
The bearing journal has metal deposits from the bearing. |
Use the part again.
Illustration 50 | g06301252 |
Buffing the Bearing Journals |
The bearing journals can be polished or machined to removed light scratches. Wheel and shaft assemblies that show light scratches or shiny areas on the bearing journals can be used again after the journals are polished and if the wheel and shaft assemblies are within the specifications of wear. Polish the bearing journals with 266-3452 Emery Polishing Paper.
The bearing journals can also be built up by using thermal spraying and then ground down to standard dimensions. For more information, refer to "Thermal Spray Procedures for Bearing Diameter of Turbocharger Turbine Wheel and Shaft Assembly".
After the bearing journals are polished, measure each journal diameter with a micrometer. If the dimension that is measured is less than the dimension that is given under the minimum diameter of the bearing journal. then the turbine wheel and the shaft assembly cannot be used again.
Note: Some bearing journals in turbochargers that have been remanufactured may be smaller than the standard size of bearing journals. Replacement bearings for these journals must be the correct size.
Illustration 51 | g03676746 |
Undersized Bearing Journal that is Marked .010". |
Some turbine shafts can have the bearing journals ground undersized and use undersized bearings. These turbine shafts have the undersized dimension etched into the shaft in the location shown in Illustration 81. Bearings can be undersized by
Illustration 52 | g01410149 |
The bearing journal has light scratches. The bearing journal can be used again if the diameter is within specifications and the bearing journal is polished with |
Use the part again after polishing.
Illustration 53 | g01410151 |
The bearing journal in Illustration 52 after the bearing journal was polished. |
Illustration 54 | g01410152 |
The bearing journal has a single deep scratch. The bearing journal can be used again if the diameter is within specifications and the bearing journal is polished. |
Use the part again after polishing.
Wheel and shaft assemblies that show discoloration, carbon deposits and/or deposits of lacquer can be used again after the wheel and shaft assemblies are cleaned. Refer to "Cleaning Procedures" in this document.
Illustration 55 | g01410153 |
The shaft shows discoloration and the shaft can be used again after the shaft is cleaned. |
Use the part again after cleaning.
Before the wheel and shaft assembly is assembled in the turbocharger, the bearing journals must be polished with 266-3452 Emery Polishing Paper. The bearing journals must be then measured with a micrometer. Finally, the bearing journals must be cleaned in a good solvent.
Illustration 56 | g03676685 |
Measuring the Shaft Diameter |
Illustration 57 | g01410155 |
The shaft was cleaned to remove discoloration, carbon deposits and/or deposits of lacquer. |
Use the part again.
The turbine shaft in Illustration 57 was cleaned. The bearing journals are in good condition and bearings with the standard-sized Internal Diameter can be used providing the bearing journal meets minimum specifications.
The seal ring groove is also in good condition and does not need further repair.
Illustration 58 | g01410156 |
The shaft shows damage from a compressor wheel that has turned on the shaft. This part can be reused if the damage can be polished out. |
Use the part again.
Illustration 59 | g01410158 |
The shaft has damage of the threads. The shaft can be made usable by the use of the correct rethreading die. |
Use the part again.
Note: Do not use wheel and shaft assemblies with severely damaged threads. Wheel and shaft assemblies that have threads which have been pulled or stretched must not be used again.
Illustration 60 | g01410159 |
The shaft is bent more than the Total Indicator Reading (TIR) but the shaft can be used again after the shaft is made straight. The TIR is |
Use the part again after the shaft is straightened.
Illustration 61 | g03678490 |
Use |
Illustration 62 | g06301257 |
Example of a V Block and Dial Indicator |
Use the 5P-6518 Dial Indicator Fixture and the following procedure to measure the bend in wheel and shaft assemblies.
- Put the wheel and shaft assembly in 5P-6518 Dial Indicator Fixture so the bearing journals are on the vee blocks.
Note: Refer to Special Instruction, SMHS6998, "Instructions For The Use Of 5P-6518 Fixture Group - Parts Reusability" for complete instructions on the use of the 5P-6518 Dial Indicator Fixture Gp.
- Put the dial indicator next to the threaded area on the shaft. Adjust the dial indicator to zero.
- Turn the wheel and shaft assembly in the Vee shaped blocks from the side with the wheel.
Note: The wheel and shaft assembly must not be pushed sideways and the wheel and shaft assembly must not be pushed down while the wheel and shaft assembly is being turned. For best results, use one finger to turn the wheel.
- While the wheel and shaft assembly is turned, look at the dial indicator to get the TIR. If the TIR is
0.05 mm (0.002 inch) or less, the wheel and shaft assembly can be used again.
Note: Do not reuse aluminum compressor wheels in certain high cyclical and high load applications.
Note: Aluminum compressor wheels must be inspected for orange peel. If aluminum compressor wheels exhibit orange peel DO NOT USE AGAIN. Orange peel is caused by overspeed of the compressor wheel.
Illustration 63 | g01410163 |
(1) Blade
(8) Nut Face (9) Bore |
Compressor wheels that have cracked blades, severely bent blades, or broken blades cannot be used again.
Compressor wheels can be reused if the blades have a slight amount of bend. Make sure that cracks are not present in the bent blades. TheZyglo procedure can be used to check for cracks if the procedure is available. If cracks are present, then the compressor wheel cannot be used again.
Illustration 64 | g03675997 |
Small lips on compressor wheel that can be felt with your fingernail USE AGAIN |
Illustration 65 | g06301260 |
Light rubbing of the compressor wheel. USE AGAIN |
Sometimes the compressor wheel has a small lip that can be felt with your fingernail. The lip is caused from a small amount of rubbing against the compressor housing. These parts can be used again after the lip from rubbing is removed from the compressor wheel and balanced.
Illustration 66 | g01410164 |
Compressor wheel had a broken blade. |
Do not use the part again.
Note: Do not straighten bent blades.
Illustration 67 | g01410165 |
The compressor wheel has one slightly bent blade. The compressor wheel does not have any cracks. |
Use the part again.
Illustration 68 | g01410168 |
Compressor wheel has severely bent blades. |
Do not use the part again.
Illustration 69 | g01410169 |
The compressor wheel has a small nick in the blade. The compressor wheel can be used again after the burrs are removed. Use a small file and |
Use the part again.
Illustration 70 | g01410187 |
Compressor wheel shows a large amount of damage from foreign material. |
Do not use the part again.
Illustration 71 | g01410189 |
Compressor wheel blades show a minor number of rubbing 360 degrees around the compressor wheel. Rebalance this component. |
Use the part again.
Illustration 72 | g01410190 |
Compressor wheel blades show a minor number of rubbing 360 degrees around the compressor wheel. Rebalance this component. |
Use the part again.
Compressor wheels that have light rubbing on the blades less than 360 degrees around the compressor wheel cannot be used again. If there are small burrs on the blades in the area of the light rubbing, then the burrs must be removed with a small file or an emery cloth that is medium grit.
Illustration 73 | g01410191 |
Compressor wheel blades show heavy rubbing. |
Do not use the part again.
A compressor wheel nut that has been tightened too much can cause damage to the face. If compressor wheels with damaged nut faces are used again, a failure to the turbocharger is possible.
Illustration 74 | g03644428 |
Compressor wheel has damage on the nut face due to slippage. Use the part again. |
Compressor wheels that have rubbing on back faces cannot be used again.
Illustration 75 | g01410194 |
Compressor wheel shows rubbing on the back face. |
Do not use the part again.
Illustration 76 | g01410195 |
The bore of the compressor wheel has grooves. (The compressor wheel was cut in half for illustration purposes.) |
Do not use the part again.
Compressor wheels that have minor amounts of axial scratches in the bore can be used again if the scratches are visible but not able to be felt with a small piece of wire. Compressor wheels that have deep grooves or other damage in the bore cannot be used again.
Note: Some compressor wheels have a hole for balance in the bore of the compressor wheel.
Illustration 77 | g01410197 |
(10) Bore of the outlet
(11) Bore of the inlet and contour (12) Vanes |
Illustration 78 | g01410198 |
The compressor housing shows damage to the vanes from foreign material. On this type of housing this damage is acceptable if it is only on 30% of the vane surface. |
Use Again
Illustration 79 | g01410200 |
The compressor housing has light pitting in the bore. |
Use the part again.
Illustration 80 | g01410201 |
The compressor housing shows damage from foreign material. If these can be buffed out the housing can be reused. |
Use Again
Compressor housings that have minor amounts of rubbing or scratches in the area of the contour of the bore can be used again.
Illustration 81 | g06301267 |
Slight rubbing in the compressor housing from contact with compressor wheel USE AGAIN |
This compressor housing has made slight contact with the compressor wheel. The amount of material removed is minimal and the groove can be felt with a fingernail. This compressor wheel can be used again after the compressor housing is cleaned and media blasted.
Illustration 82 | g01410202 |
Compressor housings show light rubbing in the area of the contour of the bore. |
Illustration 83 | g01410203 |
Compressor housings show light rubbing in the area of the contour of the bore. |
Use the part again.
Illustration 84 | g01410204 |
The compressor housing has deep grooves in the area of the contour of the bore. |
Do not use the part again.
Note: Machine T1810 compressor housings during reconditioning. Machining the compressor housings will prevent possible future damage of the bore.
Illustration 85 | g02023185 |
The dimensions are for the machining of a larger bore of the inlet on the compressor housing of T1810 turbochargers. (H) Align the bore to this face within (J) (K) (L) This area must be reworked by hand to remove the sharp change in shape from the straight bore. The area should have a minimal change in shape. |
Note: The area (L) must be reworked by hand to remove the sharp change in shape from the straight bore. The area should have a minimal change in shape.
Illustration 86 | g01410207 |
The compressor housing shows a deposit of material from the compressor wheel on the contour of the bore. The compressor housing can be used again after the deposit is removed with emery cloth that is 80 abrasive grit. Clean the housing thoroughly with solvent. |
Use the part again.
Note: Remove the deposit of material only. Do not change the shape of the contour of the bore.
Illustration 87 | g06301271 |
Compressor Housing |
The flange of the compressor housing should be inspected for damage. The flange can be welded, if necessary. Belzona can also be used for pitting on the face of the flange if required.
Illustration 88 | g03677167 |
Deburring the outlet flange of the compressor housing. |
Illustration 89 | g03677179 |
Deburring the inlet of the compressor housing. |
Illustration 90 | g03677196 |
Buffing out burrs on the inlet of a compressor housing. |
The end of the compressor housing can be lightly filed to remove any burrs that may remain after cleaning and media blasting. The bores of the compressor housing can also be lightly buffed to remove any scratches or burrs.
Compressor housings with wear in the bores for the O-rings of the inlet and/or outlet can be used again if there is good contact between the O-ring seals and the bore.
Illustration 91 | g06301273 |
(13) Inlet flange
(14) Contour of the bore |
Illustration 92 | g01410210 |
The turbine housing has a crack on the outside. |
Do not use the part again.
Illustration 93 | g01410212 |
The turbine housing has cracks only in the area of the seal flange. If the only cracks that are present are similar to crack (16,) then the housing can be used again. If the cracks are extended past the area of the seal flange, similar to cracks (15) then the housing cannot be used again. (15) Cracks that extend past the seal flange (16) Crack that does not extend past the seal flange. |
Illustration 94 | g06301275 |
Turbine Housing |
The bore in turbine housing must be checked for excessive pitting or cracks. If the pitting is excessive, then the bore can be built up with thermal spray and then machined to the correct size. For more information, refer to "Thermal Spray Procedures for Turbocharger Compressor Housing Contour Bore".
Illustration 95 | g06301277 |
Cleaning the mounting flange of a turbine housing. |
The mounting flange of the turbine housing must be smoothed and deburred to make a good surface for the gasket.
Illustration 96 | g06301280 |
Turbine Housing |
The studs on the turbine housing should always be replaced each time the turbocharger is serviced. The tapped holes in the flange should be inspected for damage. A Heli-Coil can be used to repair damaged threads, if necessary.
Illustration 97 | g06301282 |
Turbine Housing Insert |
The turbine housing insert is usually OK to use again. Check the threads of the tapped holes. A Heli-Coil can be used to repair damaged threads, if necessary.
Divided turbine housings provide significant benefits to the efficiency and response of turbochargers in the low speed range and middle speed range of the engine. Divided turbine housings are commonly used for engine applications that require a wide range of engine operating speeds. This provides optimum fuel economy and a faster response to engine load.
Cracks will form in the turbine housing from thermal mechanical fatigue during the service life of a turbocharger. An inspection of the turbine housing should be performed. Refer to Operation and Maintenance Manual for guidelines and inspection intervals. Cracks that are found in the following locations of the turbine housing may not be critical: tongue, divider wall, and heat shield bore. Use the criteria in this guideline to determine if the turbine housing can be reused. The housing should be replaced if the cracks are not acceptable according to this guideline.
Studies have shown that turbine housings tend to crack in certain areas. Cracks are typically found in the divider wall. This type of crack relieves stresses in the housing. Tests indicate that turbochargers that have cracks in the locations that are listed above can continue to operate. The cracks will not continue to grow and the performance of the turbocharger will not be affected. The cracks are normal and the durability of the turbocharger will not be affected.
The following Illustrations are provided to identify turbocharger parts. The reuse information will refer to the various parts that are identified in Illustrations 98 through 100.
Illustration 98 | g01138134 |
(1) Compressor Housing
(2) Bearing Housing (3) Turbine Housing (4) Divider Wall (5) Bearing Housing Bore (6) Inlet Flange |
Illustration 99 | g06301285 |
(4) Divider Wall
(5) Bearing Housing Bore (7) Heat Shield Bore (8) Exhaust Gas Inlet (9) Exhaust Outlet |
Illustration 100 | g06301286 |
(10) Tongue
(11) Exhaust Gas Inlet |
This document discusses cracks that can be found in the following parts of the turbine housing:
- Divider wall
- Tongue
- Heat shield bore
- Turbine housing exterior
- Exhaust gas inlet flange area
The characteristics of the cracks will determine if the turbine housing can be reused. Refer to the reuse information that is provided in this document.
Illustration 101 | g06301287 |
Illustrations 102 and 103 are enlarged from the section above. |
Illustration 102 | g06301289 |
Reusable Typical crack in the divider wall |
Illustration 103 | g06301291 |
Reusable Typical cracks in the divider wall |
The turbine housings that are represented in Illustration 102 and Illustration 103 are reusable.
Reuse criteria for cracks in the divider wall of the turbocharger housing:
Do not reuse any housing that has cracks in the divider wall closer than
- The crack is continuous through the thickness of the divider wall.
- The length of the crack is greater than
5 mm (0.1969 inch) .
There is no limit on the number of cracks in the divider wall that are allowed. However, the spacing between cracks must be evaluated. Do not reuse any housing that has cracks in the divider wall closer than
Illustration 104 | g06301293 |
Scaling corrosion should not be considered as cracking. |
Scaling due to corrosion, or cracks in the layer of corrosion on the divider wall do not count as a radial crack. Illustration 104 shows an example of a scaling corrosion which has the appearance of a crack. Scaling corrosion should not be considered as cracking.
Do not reuse the turbocharger housing if cracks with the following characteristics are found in the divider wall:
- Cracks that cause the divider wall to shift more than
2 mm (0.0787 inch) radially toward the turbine wheel should not be used. Refer to Illustrations 105 and 106. - Cracks that cause the divider wall to distort more than
2 mm (0.0787 inch) axially should not be used. Refer to Illustration 107.
Illustration 105 | g06301297 |
Do not reuse the turbocharger housing. Significant radial shift of divider wall |
Illustration 106 | g06301300 |
Do not reuse the turbocharger housing. Radial shift of divider wall |
Illustration 107 | g06301301 |
Do not reuse the turbocharger housing. Axial shift of divider wall |
Illustration 108 | g06301302 |
Illustrations 109 and 110 are enlarged from the section above. |
Illustration 109 | g06301304 |
Reusable Crack in the tongue |
Illustration 110 | g06301305 |
Reusable Crack in the tongue |
Reuse criteria for cracks in the tongue of the turbine housing:
- There should be no more than one crack in the tongue on each side of the divider wall.
- The housing is not reusable if the length of the crack is greater than
20 mm (0.7874 inch) .
Note: Reman has a length criteria of cracks that is based on part numbers, so a Reman housing may have an acceptable crack that is different than what is stated above.
Illustration 111 | g06301306 |
Illustrations 112 and 113 are enlarged from the section above. |
Illustration 112 | g06301307 |
The crack must be less than Crack in the bore of the heat shield |
Illustration 113 | g06301308 |
Reusable Crack in the bore of the heat shield |
Reuse criteria for cracks in the bore of the heat shield:
- Cracks in the bore of the heat shield should not have a gap that is greater than
1 mm (0.0394 inch) . - The length of the crack should not be greater than
20 mm (0.7874 inch) .
The following cracks in the turbine housing are not acceptable.
Do not reuse the turbine housing if the following types of cracks are found:
- Cracks that are visible on the exterior of the turbine housing should not be used. Refer to Illustrations 114,115, and 116.
- Cracks in the divider wall at the exhaust gas inlet flange should not be reused. Refer to Illustration 117.
Illustration 114 | g06301309 |
Do not reuse the turbocharger housing. Exterior crack in the inlet flange area |
Illustration 115 | g06301311 |
Do not reuse the turbocharger housing. Exterior visible cracks |
Illustration 116 | g06301312 |
Do not reuse the turbocharger housing. Exterior crack in the inlet flange area |
Illustration 117 | g06301313 |
Do not reuse the turbocharger housing. Vertical crack in divider wall of the exhaust inlet |
Note: Cracks running horizontal to the mounting face are acceptable if the crack is less than
Housings with excessive scaling or corrosion on any area of the turbine housing should not be reused. The worst scaling is typically found on the divider wall at the exhaust gas inlet.
Note: Scaling is an indication of higher than normal exhaust gas temperature. Further investigation may be necessary to determine the root cause of the scaling.
Scaling occurs as cracks develop in the layers of corrosion. The cracks allow corrosion to flake from the wall of the turbine housing. Thermal expansion and contraction during normal operation can contribute to scaling.
Illustration 118 | g06301314 |
Do not reuse the turbocharger housing. Scaling and cracking of the exhaust divider wall Material is flaking from the corroded area. |
Corrosion typically occurs in turbine housings without material that is flaking from the surface. This type of corrosion is acceptable. The surfaces that are shown in Illustration 119 and Illustration 120 are acceptable.
Illustration 119 | g06301315 |
Reusable Corrosion without material that is flaking from the housing |
Illustration 120 | g06301317 |
Reusable Corrosion without material that is flaking from the housing |
Illustration 121 | g06301318 |
Do not reuse the turbocharger housing. Corrosion of the surface with material that is flaking off |
Severe corrosion that results from higher operating temperatures will result in material that flakes off the surface of the turbine housing. This level of corrosion is unacceptable. The housing should not be reused.
During the service life of the turbocharger, cracks from high temperatures may form in the housing. The housing's should be inspected. To inspect the housings, follow the guidelines in the Operation and Maintenance Manual and inspection intervals. If cracks are found and the cracks are in the area of the tongue of the turbocharger housing, the cracks may not be critical. The reusability of the turbocharger housing is determined by comparing the length of the crack and the width of the crack to the specifications, If a crack exceeds the maximum length of the crack or maximum width of the crack, then the housing must be replaced.
This section can be used to inspect 7E-2744 Turbocharger Housings or similar ABB Turbocharger Housings.
Note: If cracks are found in a location that is not shown in the guideline, then the issue should be directed to the dealer solution network through the technical communicator at the dealership. This will help determine if the turbocharger housing is reusable.
Illustration 122 | g01500898 |
These locations are typical for cracks. Refer to Table 5 for acceptable lengths of cracks. |
Illustration 123 | g01502362 |
The illustration shows specifications for the length of the crack. Refer to Table 5. |
Specifications for the Maximum Crack Length | ||
---|---|---|
Area | Specification | |
(A) | Length | |
Width | |
|
(B) | Length | |
Width | |
|
(C) | Length | |
Width | |
|
(D) | Length | |
Width | |
Do not reuse housings that have transverse cracks (2) (Table 124) onto the wall of the housing (perpendicular to the wall). If two or more cracks come to a merge (1) (Table 124), the housing should not be reused. Cracks that come to a merge can result in breakouts of the housing.
Illustration 124 | g01502381 |
Cracks that come to a merge (1) and transverse cracks (2). |
Do not use the part again.
Illustration 125 | g01502382 |
Cracks that come to a merge |
Do not use the part again.
Do not use the housing again when cracks come to a merge. Cracks that come to a merge can allow material between the cracks to break free resulting in possible damage to the engine.
Illustration 126 | g01502383 |
The crack in area (D) does not exceed the specification in length. |
Use the part again.
Illustration 127 | g01502384 |
Crack in area (D). |
Do not use the part again.
Do not use the housing again if the width of the crack exceeds
Illustration 128 | g01502385 |
Crack in area (D). |
Do not use the part again.
Do not use the housing again if the width of the crack exceeds
Illustration 129 | g01502387 |
Crack in area (B). |
Use the part again.
Use the part again if the length of the crack (E) does not exceed
Illustration 130 | g01502390 |
The crack starts in area (A) and the crack extends into area (B). |
Do not use the part again.
Do not use the part again if the width of the crack exceeds
Illustration 131 | g01502392 |
Crack in area (B). |
Do not use the part again.
Do not use the part again if the length of the crack (E) exceeds
Illustration 132 | g01502395 |
Crack in area (A). |
Use the part again.
Use the part again if the width of the crack is less than
Illustration 133 | g01502397 |
Crack in area (C). |
Use the part again.
Use the part again if the length of the crack does not exceed
Illustration 134 | g01410688 |
The exhaust housing has broken bolts and the exhaust housing can be used again after the broken bolts are removed. The threads in the bolt holes must be checked for damage. Repair the threads of the bolt holes if the threads need to be repaired. |
Use the part again.
Illustration 135 | g01410214 |
The turbine housing has minor amounts of erosion on the contour of the bore. |
Use the part again.
Illustration 136 | g01410215 |
The turbine housing has heavy erosion on the contour of the bore. |
Do not use the part again.
Turbine housings that have light rubbing or scratches on the area of the contour of the bore can be used again. Turbine housings that have heavy rubbing or deep grooves on the area of the contour of the bore cannot be used again.
Illustration 137 | g01410216 |
The turbine housing shows a deposit of material of the turbine wheel on the contour of the bore. The housing can be used again after the deposit is removed. |
Use the part again.
Note: Remove the deposit of material only. Do not change the shape of the contour of the bore.
Some inlet flanges have a web that divides the inlet opening in half. Exhaust housings with erosion on this web cannot be used again.
The inlet flange must be checked for flatness. A straight edge and a feeler gauge should be used to measure the width and the length of the inlet flange. If the amount of warp is more than
Illustration 138 | g01410217 |
The turbine housing shows erosion on the web and cracks in the inlet flange. The cracks go into the area of the gasket. |
Do not use the part again.
Turbine housings with wear in the bore of the outlet can be used again if there is good contact between the seal rings and the bore.
Illustration 139 | g01410218 |
(17) Bore
(18) Oil hole |
Illustration 140 | g06301509 |
The center housing was cut in half for illustration purposes. (19) Bore for the oil seal ring (20) Cavity for oil supply (21) Back cavity of the oil drain (22) Snap ring grooves (23) Bearing bores |
Illustration 141 | g01410220 |
The center housing has a damaged snap ring groove. |
Do not use the part again.
Center housings that have deep grooves or excessive damage to the seal ring bore cannot be used again.
A center housing with a bore for the seal ring that has a minor number of scratches can be used again after the seal ring bore is cleaned and measured. Use 266-3452 Emery Polishing Paper to clean the seal ring bore.
Measure the bore with the 5P-2170 Dial Bore Gauge and the correct master ring. Center housings with a bore for the seal ring that is larger than the dimension cannot be used again.
Illustration 142 | g01410221 |
The center housing has a bore for the seal ring with excessive damage. |
Do not use the part again.
Center housings cannot be used again if center housings have deep scratches or grooves around the bearing bores. If a few deep scratches or grooves come out of the cavity for oil supply then the center housing can be used again.
Illustration 143 | g06301517 |
Inspecting the Bearing Bore Area USE AGAIN |
Illustration 144 | g06301519 |
A Bearing Bore on Water-Cooled Center Housings |
Inspect the bearing bore for heavy scratches, a groove, or excessive wear.
Illustration 145 | g06301521 |
Using A Bore Gage in the Bearing Bore of the Center Housing |
Illustration 146 | g06301524 |
Measuring the Bore Gage |
Some cartridge housings have the bearing bore diameters machined oversized and use oversized bearings. The bearing bores can be oversized by
Illustration 147 | g01410223 |
The bearing bore in the center housing shows deep scratches and grooves. |
Do not use the part again.
Illustration 148 | g01410224 |
A few deep scratches come from the cavity for oil supply. |
Use the part again.
Illustration 149 | g01410225 |
The bearing bore in the center housing has light scratches and shiny areas. The housing can be used again after the housing is cleaned and if the bearing bore diameter is within specifications. |
Use the part again.
Illustration 150 | g01410226 |
The bearing bore in the center housing shows discoloration. The bearing bore can be used again after the housing is cleaned and if the bearing bore diameter is within specifications. |
Use the part again.
Polish the bearing bores with 266-3452 Emery Polishing Paper. Measure the inside diameter of the bores with the 5P-2170 Dial Bore Gauge. The bores on turbocharger models T04 and T04B must be measured with a telescoping gauge and a micrometer. Center housings with bearing bores that are larger than the dimensions cannot be used again.
Note: In some turbochargers that have been remanufactured, the diameter of the bearing bore may be larger than the standard size. Replacement bearings for these bores must be the correct size.
Center housings that show light erosion can be used again. Center housings that show heavy erosion cannot be used again.
Clamp plates hold the center housing to the exhaust housing on T 1200 series of turbochargers. If these clamp plates show excessive wear, then the clamp plates cannot be used again. The clamp plates can also cause wear to the mounting flange of the center housing. The thickness of the flange must be measured to find out if a center housing with wear on the mounting flange can be used again. Measure the thickness of the flange at a point approximately
Illustration 151 | g01410227 |
The center housing shows light erosion. |
Use the part again.
Illustration 152 | g01410228 |
The center housing shows heavy erosion. |
Do not use the part again.
Some turbocharger center housings have retaining pins that are hollow. Center housings with hollow pins that are damaged can be made usable by the installation of new solid pins.
Center housings that have damaged pins or broken pins cannot be used again.
Illustration 153 | g01410229 |
The center housing has damaged retaining pins of the thrust washer. |
Do not use the part again.
- Remove the damaged pins or the broken pins with a sharp chisel and a hammer. Be careful not to damage the contact surface of the thrust washer. If the surface is damaged, the thrust bearing will not lie flat.
- Grind any remaining part of the pins so the pins are even with the surface of the center housing. There must not be any of the pin above the surface of the center housing.
- Put the turbine wheel and shaft assembly in position on the correct service tool of the turbine holder. Install the turbine and end bearing on the shaft assembly.
- Install the center housing with the damaged pins on the shaft assembly.
- Install the compressor end bearing on the shaft assembly.
- Put a new thrust washer in position on the center housing so the holes in the washer are in alignment with the old pins. The thrust washer must be turned 15 degrees in the counterclockwise direction. Make sure that the center of the thrust washer is the same distance from the shaft at all points.
Note: Grease can be applied on the bottom of the thrust washer to keep the thrust washer in the center position. Be sure to remove the grease with solvent before the turbocharger is assembled.
- Use a punch to make a mark for the location of the installation of the new pins on the center housing.
- Drill the two holes for the new pins. The two holes should have a
2.405 ± 0.023 mm (0.0947 ± 0.0009 inch) diameter. The depth of the two holes should be5.00 ± 0.20 mm (0.1969 ± 0.0079 inch) . Drill a3.40 ± 0.51 mm (0.1339 ± 0.0201 inch) diameter by a 45 degrees counterbore. - Install new 4M-6646 Grooved Pins. The grooved end of the pin should be installed in the center housing. The pins must not be above the thrust washer after the washer is installed on the pins.
Illustration 154 | g01410230 |
The thrust collar has deep scratches and grooves. Do not machine the thrust collar to remove wear. |
Do not use the part again.
Illustration 155 | g01410231 |
The thrust collar has light scratches and the thrust collar can be used again after the thrust collar is cleaned with |
Use the part again.
Illustration 156 | g01410232 |
The thrust collar has shiny areas and the thrust collar can be used again after the thrust collar is cleaned with |
Use the part again.
The thrust rings will show the same type of wear as the thrust collars. if a face of a thrust ring becomes worn the ring can be turned over so the opposite face will get the wear.
Illustration 157 | g01410233 |
The thrust ring has deep scratches and grooves. The thrust ring can be used again after the thrust ring is turned over. |
Use the part again.
Illustration 158 | g01410234 |
The wheel shroud has a crack. |
Do not use the part again.
Illustration 159 | g01410235 |
The wheel shroud shows excessive erosion. |
Do not use the part again.
Illustration 160 | g01410236 |
The wheel shroud shows damage from contact of the shaft. |
Do not use the part again.
Illustration 161 | g01410237 |
The wheel shroud has discoloration and the wheel shroud can be used again after the wheel shroud is cleaned. |
Use the part again.
Wheel shrouds that show discoloration can be used again after wheel shrouds are cleaned.
Illustration 162 | g01410238 |
The wheel shroud has discoloration. Half of the shroud has been cleaned with glass beads. |
Use the part again.
Most turbochargers use either a flinger sleeve or a thrust spacer at the compressor end of the shaft assembly.
The seal ring grooves in these parts must be checked for excessive wear. If there is excessive wear in the seal ring grooves, the parts cannot be used again. Use the procedure that follows to measure the width of the seal ring grooves.
- Make sure that the seal ring grooves are clean and free of carbon.
- Measure the width of a new seal ring. Record this dimension.
Note: Some of these parts use two seal rings in the same groove. A measurement of both seal rings is necessary.
- The seal rings are then installed into the seal ring groove that will be measured. Measure the clearance between the seal ring and the side wall of the groove with a feeler gauge.
- Add this dimension to the dimension for the width of the seal ring or rings. This dimension will be the width of the seal ring groove.
If the width of the seal ring groove is more than the dimension that is given in Reuse and Salvage Guideline, SEBF8019, "Specifications for Reusable Turbocharger Components", then the flinger sleeve or the thrust spacer cannot be used again.
Illustration 163 | g01410239 |
The flinger sleeve shows no wear and the seal ring groove is within specifications. |
Use the part again.
Illustration 164 | g01410240 |
The thrust spacer shows no wear and the seal ring grooves are within specifications. |
Use the part again.
Some turbochargers have an insert at the compressor end of the shaft assembly.
Illustration 165 | g01410242 |
The insert shows wear in the area of the bore. |
Do not use the part again.
Illustration 166 | g01410243 |
The insert shows no wear in the area of the bore. |
Use the part again.
Illustration 167 | g06301528 |
Compressor Insert |
The compressor insert should be cleaned and inspected. Check the internal surface for nicks and scratches. Inspect the seal groove for dents or other damage.
Illustration 168 | g03676801 |
Gap between rivet and the thrust plate. DO NOT USE AGAIN |
Some backing plates have the thrust plate built into the plates and held in place with rivets. If the thrust plate can be rotated because of a gap between the rivets and the plate, the backing plate must be replaced with new. More wear will result in excessive movement in the thrust plate and could cause the rivets to shear off causing damage.
Illustration 169 | g01410244 |
The thrust plate has discoloration, light scratches, and shiny areas on the washer. The thrust plate also shows shiny areas in the bore. |
Use the part again.
Illustration 170 | g01410247 |
The thrust plate shows deep scratches and grooves in the washer. |
Do not use the part again.
Illustration 171 | g01410245 |
The thrust plate shows excessive wear in the bore. The thrust plate also shows cracks in the bore. |
Do not use the part again.
Illustration 172 | g01410248 |
The washer on the thrust plates has turned. The washer is over part of the pins that hold the washer. |
Do not use the part again.
Illustration 173 | g01410249 |
Use a can of oil to check the oil holes. The oil holes must be clean and free of erosion. |
Note: The washer of the thrust plate is held by pins. Make sure that the washer is tight. Hold the washer by the center flange and try to move the washer. If the washer can be moved by this method, the thrust plate cannot be used again. If the thrust plate can be used, clean the thrust plate in a heavy-duty carbon solvent, and put lightweight oil on the thrust plate to prevent rust.
Thrust bearings that show deep scratches, grooves, or excessive wear on either face cannot be used again. Wear across the full face of the thrust washer is not allowed. There is a ramp that controls oil flow to the flat. No damage can be on the ramp. Slight wear or light damage on the face is acceptable.
Illustration 174 | g01410250 |
Thrust bearing shows light wear. |
Use the part again.
Illustration 175 | g01410251 |
Thrust bearing shows light wear. |
Use the part again.
Illustration 176 | g01410252 |
Thrust bearing shows light wear. |
Use the part again.
Illustration 177 | g01410253 |
Thrust bearing has deep scratches and grooves. Check the oil hole with a wire. Oil hole must be open and free of foreign material. |
Use the part again.
Illustration 178 | g01410255 |
Check the oil hole with a wire. Oil hole must be open and free of foreign material. |
Do not use the part again.
If the thrust bearing can be used again, then clean the thrust bearing in a heavy-duty carbon solvent before the thrust bearing is installed in the turbocharger.
Illustration 179 | g06301555 |
Diffuser Ring |
The diffuser ring is normally OK to use again. Check the fins for damage and straightness.
Illustration 180 | g06301558 |
Seals and Rings |
The seals and the rings should ALWAYS be replaced with new. NEVER Reuse the old seals or the old rings.
Illustration 181 | g06301562 |
Nozzle Ring |
The nozzle ring can be cleaned with plastic media blasting and used again. Check the fins for damage and check the seal groove for damage such as dents or cracks.
Turbo Specifications & Reusability for 3600 Engines
Turbine Shaft and Wheel Assembly for 3600 Engines
Illustration 182 | g06301578 |
Turbine shaft and wheel assembly with detail of seal ring groove. |
Turbine Shaft And Wheel Assembly Dimensions | |||
---|---|---|---|
Item | Nomenclature | New Dimension | Reuse Dimension(1) |
A | Shaft Length | |
N/A |
B | Blade Diameter | |
|
C | Compressor Bearing Journal Diameter | |
|
D | Turbine Bearing Journal Diameter | |
|
E | Turbine Hub Diameter | |
|
F | Seal Ring Groove Width | |
|
(1) | Minimum allowable dimension is shown unless noted otherwise. |
Compressor Wheel for 3600 Engines
Illustration 183 | g06301619 |
Compressor wheel with detail of seal ring groove. |
Compressor Wheel Dimensions | |||
---|---|---|---|
Item | Nomenclature | New Dimension | Reuse Dimension |
G | Seal Ring Groove Width | |
|
H | Hub Diameter | |
|
Turbine Shaft Bearings for 3600 Engines
Illustration 184 | g06301629 |
Turbine shaft bearings. |
Turbine Shaft Bearing Dimensions | |||||
---|---|---|---|---|---|
Part | J | K | L | ||
New | Minimum Reuse | New | Maximum Reuse | New | |
Turbine | |
|
|
|
|
Compressor | |
|
|
|
|
Thrust Bearing Seat Dimension for 3600 Engines
Illustration 185 | g06301631 |
Thrust bearing seat dimension. (M) Seat dimension |
Thrust Bearing Seat Dimension | |
---|---|
New | Maximum Reuse |
|
|
Procedure to Measure Thrust Bearing Surface for 3600 Engines
- The angle of the wedge surface for the thrust bearing must be measured for maximum allowable wear. The angle of a new thrust bearing as measured from the centerline of the bearing is 67.5 degrees. See Illustration 186.
- The maximum allowable wear is 50° as measured from the centerline of the bearing. See Illustration 186.
- Make a plastic overlay of Illustration 187. and use to measure the wear on the thrust surface. The illustration is the actual size required. If the wear pattern is less than 50°, the thrust bearing must be replaced with a new one.
Illustration 186 | g06301638 |
Angle of wedge surface when new and maximum allowable wear of wedge surface of thrust bearing. (N) Minimum angle of wedge surface 50°. (P) New angle of wedge surface 67.5°. |
Illustration 187 | g06301641 |
Make a template of this drawing to measure thrust bearing wear. |
Compressor Bearing Bore Diameter
Illustration 188 | g06301643 |
Compressor bearing bore diameter. |
Compressor Bearing Bore Diameter Dimensions | |
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New | Maximum Reuse |
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Turbine Bearing Bore Diameter for 3600 Engines
Illustration 189 | g06301646 |
Turbine bearing bore diameter. |
Turbine Bearing Bore Diameter Dimensions | |
---|---|
New | Maximum Reuse |
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Turbocharger Bearing Clearance for 3600 Engines
Radial Dimension
Illustration 190 | g06301652 |
Turbocharger bearing clearance radial dimension. |
- Mount a magnetic base dial indicator on the center section housing and position the indicator tip against the impeller hub end diameter.
- Move the impeller end of the turbine shaft up. Move the turbine end down. Zero set the dial indicator.
- Move the impeller end of the turbine shaft down. Move the turbine end up. Observe the indicator reading. Refer to Table 12 for minimum and maximum clearance specifications.
Turbocharger Bearing Clearance | ||
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New | Maximum Reuse | |
Radial Dimension | |
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End Play
Illustration 191 | g06301657 |
Turbocharger bearing clearance end play. |
- Mount a magnetic base dial indicator on the center section housing. Position the indicator tip against the impeller hub end surface.
- Move the turbine shaft toward the turbine end. Zero set the dial indicator.
- Move the turbine shaft toward the impeller end. Observe the indicator reading. Refer to Table 13 for minimum and maximum clearance specifications.
Turbocharger Bearing Clearance (End Play) | ||
---|---|---|
New | Maximum Reuse | |
End Play | |
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Rotating Assembly Balance Specifications for 3600 Engines
Illustration 192 | g02147073 |
Rotating assembly. |
At the completion of the manufacturing process, the turbine shaft and compressor wheel are separately balanced prior to assembly.
Once in operation, various factors can cause the turbocharger rotating assembly to become unbalanced, making it necessary to disassemble and repair the components. Whenever the rotating assembly has been disassembled, the components of the rotating assembly must be balanced.
Factors Which May Cause Unbalance of Rotating Assembly for 3600 Engines
- Mechanical damage caused by foreign particles
- Uneven deposits of dirt
- Erosion of the blade edges on the components caused by the presence of solid particles in the intake air or exhaust gas.
Rebalancing is required when:
- There is visible mechanical damage to the turbine shaft and/or compressor wheel
- When the turbine shaft has been rebladed
- When the turbine shaft and/or compressor wheel have been repaired/machined
Balancing for 3600 Engines
The following instructions outline the methods, tooling, equipment, specifications, and procedures required to balance the individual components and rotating assembly.
Balancing Machine Requirements
- Force-measuring
- Two plane measuring
- Hard bearing (adjustable height)
- Belt Drive
- Minimum achievable residual unbalance 0.2 g/kg (0.007 oz/lb)
- Minimum table clearance
305 mm (12.0 inch) - Minimum weight capacity
32 kg (70 lb)
Procedure to Balance Turbine Shaft
Illustration 193 | g06301659 |
Turbine shaft installed on balancing machine. |
- When balancing, use a clean shaft with no seal ring installed.
- Position the turbine shaft on the balancing machine bearings. See Illustration 193, (R) and, (S).
Note: The shaft contains two different diameter bearing journals requiring balancing machine hard bearing adjustment.
- Position the drive belt at location (T), See Illustration 193.
- Balance the shaft, allowing for the setting. See Illustration 194, (Z), (X), (W), (Y). Refer to Table 14. The residual unbalance should be lower than the specification measured in planes "AA/AB" in Illustration 194.
Show/hide table
Table 14 Balancing Specifications Max Residual Unbalance (U) (V) (W) (X) (Y) (Z) 25 mm 33.5 mm
(1.32 inch) 43.0 mm
(1.69 inch) 82.5 mm
(3.25 inch) 28.5 mm
(1.12 inch) 67.0 mm
(2.64 inch) 231.0 mm
(9.10 inch) Show/hide tableIllustration 194 g06301663 Turbine shaft balance specifications. - If material must be removed from the shaft, only remove material from the areas specified in Illustration 195. See also Table 15.
Illustration 195 | g06301665 |
Location for removing material. |
Location For Removing Material | |
---|---|
(AD) | Minimum Distance To Surface (AC) |
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Procedure To Balance Compressor Wheel
Illustration 196 | g02147234 |
Compressor wheel installed on balancing machine. |
- Balance the compressor wheel on a clean wheel with no seal ring installed.
- Balance the compressor wheel using a balancing mandrel as shown in Illustration 194. Position the compressor wheel on the balancing machine bearings at locations (AE) and (AF) shown in Illustration 196.
- Position the drive belt at location (AG), Illustration 196, on the balancing mandrel.
- Balance the compressor wheel, allowing for the settings (AH), (AK), (AM), (AN) and (AP) shown in Illustration 197. The residual unbalance should be lower than the specification measured in planes (AJ) and (AL), Illustration 197, found in Table 16.
Show/hide table
Table 16 Chart 11. Compressor Wheel Balance specifications Maximum Residual Unbalance (AH) (AK) (AM) (AN) (AP) 30 mm 78.6 mm
(3.10 inch) 124.5 mm
(4.90 inch) 122.4 mm
(4.82 inch) 100.0 mm
(3.94 inch) 205.0 mm
(8.07 inch) Show/hide tableIllustration 197 g02147253 Compressor wheel balancing specifications. - If material must be removed from the wheel, only remove material from the areas specified in Illustration 198. See Table 17.
Illustration 198 | g06301669 |
Location for removing material. |
Location for removing material from compressor wheel | ||
---|---|---|
Boss Casting Height | (AR) - Minimum Distance to Wheel | (AS) - Minimum Thickness Allowed |
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Procedure To Balance Rotating Assembly for 3600 Engines
Illustration 199 | g06301672 |
Securing the turbine shaft. |
After separately balancing the turbine shaft and compressor wheel, assemble the parts using the same tooling and procedures outlined in the service manual. Place the shaft in a vice with soft jaws. See Illustration 199. Assemble the compressor wheel on the shaft.
Illustration 200 | g02148364 |
Rotating assembly installed on a balancing machine. |
- For balancing, the rotating assembly should be clean with no seal rings installed.
- Position the rotating assembly on the balancing machine bearings shown in Illustration 200, (R), and (S).
- Position the drive belt at location (T), Illustration 200. The shaft contains two different diameter bearing journals which require balancing machine hard bearing adjustment.
- Balance the rotating assembly, allowing for the settings in Illustration 201, (AT), (AY), (AU), (AV, and) (AW). The residual unbalance should be lower than the specification measured on planes (AX) and (AZ), Illustration 201, and Table 18.
- If material must be removed from the wheel, only remove material from the areas specified in Illustrations 195 and 198.
- Before removing the assembly, place a mark, using a felt-tip pen, on the shaft and compressor wheel (see Illustration 202). The mark will help in the realignment of the rotating assembly during installation into the turbocharger housing.
Balance Specifications for 3600 Engines
Illustration 201 | g02148366 |
Rotating assembly balancing specifications. |
Assembled Rotating Assembly Balance Specifications | |||||
---|---|---|---|---|---|
Maximum Residual Unbalance | (AT) | (AY) | (AU) | (AV) | (AW) |
46.5 mm | |
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Illustration 202 | g06301675 |
Rotating assembly alignment. |
Reuse Specifications for Turbine Wheel and Shaft Assemblies
Illustration 203 | g06300101 |
Flow chart for determining correct journal bearings. |
Illustration 204 | g06301678 |
Illustration 205 | g06301680 |
Serviceable Cartridge Number | Shaft Bearing Journal Min Diameter (A) | Turbine Shaft Hub Min Diameter (B) | Turbine Seal Groove Max Width (C) | Bearing Housing Bearing Bore Max Diameter (D) | Bearing Housing Turbine Seal Bore Max Diameter (E) | Compressor Seal Bore in Backing Plate Max Diameter |
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There are two types of torque procedures for turbos. One uses a seating torque, final torque along with a final torque turn measured in degrees. The other uses a standard torque value.
Bored compressor wheels that are captured by a nut should be torqued with the seating torque to seat the assembly and then remove the nut. Once the nut is removed apply a drop of Loctite 243 to the threads of the shaft near where the nut seats on the compressor wheel. Install the nut and torque to final torque followed by the final torque turn angle.
Boreless compressor wheels are threaded and do not use a nut to capture the compressor wheel. Before installing the compressor wheel apply a drop of DEO to the shaft threads. Torque the compressor wheel to the specified torque value below.
Serviceable Cartridge Number | Thrust Bearing Bolt Torque | Backplate Bolt Torque | Bearing Anti-Rotation Pin Torque (1) | Compressor Wheel/Nut Torque (2) | Turbine Wheel Balance at Nose (g*in) (3) | Compressor Wheel Balance at Nose (g*in) (4) |
---|---|---|---|---|---|---|
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.138 | 0.252 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.138 | 0.252 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
0.063 | 0.168 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.138 | 0.252 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
0.063 | 0.140 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
0.063 | 0.140 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
0.063 | 0.140 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
0.063 | 0.140 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
0.063 | 0.140 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.055 | 0.022 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
|||
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 95–105 Degrees |
|||
|
|
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.095 | 0.231 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.138 | 0.315 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.095 | 0.231 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 120-130 Degrees |
0.240 | 0.420 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 120-130 Degrees |
0.210 | 0.378 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 95–105 Degrees |
0.100 | 0.350 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.055 | 0.022 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
0.063 | 0.140 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
0.063 | 0.140 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
0.063 | 0.140 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
0.100 | 0.350 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
|||
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|
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
|||
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.138 | 0.252 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.138 | 0.252 | |
|
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
||||
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.055 | 0.022 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.055 | 0.022 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.138 | 0.252 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.138 | 0.252 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.088 | 0.231 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
0.063 | 0.140 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
0.063 | 0.140 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
0.063 | 0.140 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
|||
|
|
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
0.063 | 0.140 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.014 | 0.252 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
|||
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.055 | 0.022 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
0.063 | 0.140 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.138 | 0.252 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
0.063 | 0.140 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
0.063 | 0.140 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 95–105 Degrees |
|||
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
|||
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
0.063 | 0.140 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
0.063 | 0.140 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
|||
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.014 | 0.252 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
|||
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.138 | 0.252 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.138 | 0.252 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.138 | 0.252 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
0.063 | 0.140 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.014 | 0.252 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 120-130 Degrees |
0.210 | 0.420 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 120-130 Degrees |
0.210 | 0.420 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 120-130 Degrees |
0.240 | 0.420 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 120-130 Degrees |
0.210 | 0.420 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.095 | 0.231 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 120-130 Degrees |
0.210 | 0.420 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.138 | 0.315 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.138 | 0.315 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.138 | 0.315 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.095 | 0.231 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.138 | 0.315 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.138 | 0.315 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.095 | 0.231 | |
|
|
N/A | |
0.138 | 0.231 | |
|
|
N/A | |
0.138 | 0.231 | |
|
|
N/A | |
0.138 | 0.231 | |
|
|
N/A | |
0.138 | 0.231 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.088 | 0.231 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.095 | 0.231 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 120-130 Degrees |
0.240 | 0.420 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.014 | 0.252 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.165 | 0.315 | |
|
|
N/A | |
0.095 | 0.210 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 125-135 Degrees |
0.063 | 0.168 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.138 | 0.252 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.095 | 0.231 | |
|
|
N/A | |
0.138 | 0.420 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 120-130 Degrees |
0.210 | 0.420 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.095 | 0.231 | |
|
|
N/A | |
0.210 | 0.483 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 120-130 Degrees |
0.210 | 0.420 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.138 | 0.315 | |
|
|
N/A | |
0.165 | 0.420 | |
|
|
N/A | |
0.138 | 0.378 | |
|
|
N/A | |
0.118 | 0.175 | |
N/A | |
N/A | Seating Torque Final Torque Final Torque Turn 95–105 Degrees |
0.037 | 0.070 | |
|
|
N/A | |
0.247 | 0.670 | |
|
|
N/A | |
0.247 | 0.525 | |
|
|
N/A | |
0.200 | 0.350 | |
|
|
N/A | |
0.138 | 0.280 | |
|
|
N/A | |
0.247 | 0.525 | |
|
|
N/A | |
0.200 | 0.350 | |
|
|
N/A | |
0.307 | 0.350 | |
|
|
N/A | |
0.225 | 0.525 | |
|
|
N/A | |
0.210 | 0.420 | |
|
|
N/A | |
0.307 | 0.350 | |
|
|
N/A | |
0.138 | 0.280 | |
|
|
N/A | |
0.100 | 0.231 | |
|
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N/A | |
0.118 | 0.280 | |
|
|
N/A | |
0.095 | 0.196 | |
|
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N/A | |
0.118 | 0.175 | |
|
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N/A | |
0.118 | 0.175 | |
|
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N/A | |
0.100 | 0.175 | |
|
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N/A | |
0.118 | 0.231 | |
|
|
N/A | |
0.149 | 0.300 | |
|
|
N/A | |
0.100 | 0.175 | |
|
|
N/A | |
0.138 | 0.280 | |
|
|
N/A | |
0.100 | 0.205 | |
|
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N/A | |
0.136 | 0.298 | |
|
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N/A | |
0.307 | 0.350 | |
|
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N/A | |
0.100 | 0.175 | |
|
|
N/A | Seating Torque Pre-Torque Final Torque |
0.520 | 1.120 | |
|
|
N/A | |
0.100 | 0.175 | |
|
|
N/A | |
0.100 | 0.175 | |
|
|
N/A | |
0.083 | 0.203 | |
|
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N/A | |
0.225 | 0.525 | |
|
|
N/A | |
0.136 | 0.298 | |
|
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N/A | |
0.186 | 0.300 | |
|
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N/A | |
0.083 | 0.175 | |
|
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N/A | |
0.083 | 0.175 | |
|
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N/A | |
0.083 | 0.175 | |
|
|
N/A | |
0.083 | 0.175 | |
|
|
N/A | |
0.138 | 0.280 | |
|
|
N/A | |
0.118 | 0.231 | |
|
|
N/A | |
0.210 | 0.420 | |
|
|
N/A | |
0.109 | 0.203 | |
|
|
N/A | |
0.100 | 0.175 | |
|
|
N/A | |
0.138 | 0.280 | |
|
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N/A | |
0.083 | 0.175 | |
|
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N/A | |
0.118 | 0.175 | |
|
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N/A | |
0.083 | 0.175 | |
|
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N/A | |
0.083 | 0.175 | |
|
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N/A | |
|||
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N/A | |
0.139 | 0.280 | |
|
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N/A | |
0.118 | 0.175 | |
|
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N/A | |
0.136 | 0.300 | |
|
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N/A | |
0.225 | 0.475 | |
|
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N/A | |
0.109 | 0.175 | |
|
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N/A | |
0.138 | 0.280 | |
|
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N/A | |
0.095 | 0.175 | |
|
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N/A | |
0.095 | 0.175 | |
|
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N/A | |
0.138 | 0.280 | |
|
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N/A | |
0.109 | 0.203 | |
|
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N/A | |
0.095 | 0.175 | |
|
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N/A | |
0.138 | 0.525 | |
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N/A | |
0.109 | 0.175 | |
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N/A | |
0.095 | 0.280 | |
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N/A | |
0.100 | 0.350 | |
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N/A | |
0.100 | 0.350 | |
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N/A | |
0.100 | 0.350 | |
|
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N/A | |
0.138 | 0.490 | |
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N/A | |
0.083 | 0.350 | |
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N/A | |
0.083 | 0.350 | |
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N/A | |
0.100 | 0.490 | |
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N/A | |
0.136 | 0.300 | |
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|
0.560 | 1.500 | |
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0.265 | 0.700 | |
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0.650 | 1.785 | |
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0.450 | 1.225 | |
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N/A | |
0.180 | 0.490 | |
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N/A | |
0.215 | 0.420 | |
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N/A | |
0.215 | 0.420 | |
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0.650 | 1.785 | |
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N/A | |
|||
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0.325 | 0.945 | |
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0.325 | 0.945 | |
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N/A | |
0.138 | 0.280 | |
|
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N/A | |
0.187 | 0.545 | |
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N/A | |
|||
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N/A | |
0.083 | 0.350 | |
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N/A | |
0.187 | 0.545 | |
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N/A | |
0.083 | 0.350 | |
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N/A | |
0.187 | 0.545 | |
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0.310 | 0.805 | |
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0.650 | 1.785 | |
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0.650 | 1.785 | |
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0.560 | 1.500 | |
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0.450 | 1.225 | |
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N/A | |
0.083 | 0.350 | |
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N/A | |
0.118 | 0.175 | |
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N/A | |
0.215 | 0.420 | |
|
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N/A | |
0.225 | 0.475 | |
|
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N/A | |
0.281 | 0.805 | |
|
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N/A | |
0.184 | 0.545 | |
|
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N/A | |
0.184 | 0.490 | |
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N/A | |
0.184 | 0.490 | |
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|
0.310 | 0.945 | |
|
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N/A | |
0.092 | 0.447 | |
|
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N/A | |
0.215 | 0.420 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.138 | 0.315 | |
|
|
N/A | |
0.138 | 0.280 | |
|
|
N/A | |
0.265 | 0.700 | |
|
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|
0.560 | 1.500 | |
|
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|
|
0.450 | 1.225 | |
|
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|
|
0.650 | 1.785 | |
|
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|
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0.650 | 1.785 | |
|
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|
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0.650 | 1.785 | |
|
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|
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0.560 | 1.500 | |
|
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|
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0.450 | 1.225 | |
|
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|
|
0.310 | 0.945 | |
|
|
N/A | Seating Torque Final Torque Final Torque Turn 135-145 Degrees |
0.138 | 0.315 | |
|
|
N/A | |
0.138 | 0.280 | |
|
|
|
|
0.650 | 1.785 | |
|
|
N/A | |
0.095 | 0.175 | |
|
|
N/A | |
0.138 | 0.280 |
(1) | Anti rotation pins are used with Multi Lobe Semi Floating (MLSF) bearing systems. |
(2) | When three torque values are show it should be followed as Seating Torque, Final Torque and Torque Turn. Single values are a standard torque procedure. |
(3) | The balance value is the maximum permissible imbalance. |
(4) | The balance value is the maximum permissible imbalance. |
Repair Procedures and Pre-Assembly Procedures
Center Section
Illustration 206 | g06301519 |
Bearing Bore in a Water-Cooled Center Section |
The bore for the bearings can be machined to an oversized dimension. The bearing bores can be oversized by
Illustration 207 | g03676811 |
Checking the gap in the seal ring with a feeler gage |
Install a new seal ring in the center section. Use a feeler gage to check the gap of the oil seal ring. Refer to the specifications manual for your turbocharger for the maximum permissible gap.
Illustration 208 | g06301743 |
800 grit sandpaper that is soaked with clean engine oil can be used to clean up any small scratches in the seal bore that is present from media blasting.
Repairing the Turbine Shaft and Compressor Wheel
There are two areas of the turbine shaft that can be salvaged, the bearing journals and some seal ring grooves.
Thrust Bearing
The thrust bearing and the rivet studs on some backing plates are available separately. For these backing plates, the thrust bearing can be replaced. Use the following procedure to salvage the backing plate.
- Drill out and remove the three rivet studs (1) and remove the damaged thrust bearing (2). Grind the rivet studs flush with the backing plate or drive the rivet studs flush with the backing plate.
- Rotate the new thrust bearing (2) so that the new mounting holes are not aligned with the former holes for the rivet studs (2).
- Press the new thrust bearing (2) flush with the mounting surface of the backing plate. Drill three new holes for the studs and install new rivet studs.
Illustration 209 | g03677777 |
Balancing the Turbine Shaft and the Compressor Wheel
Caterpillar recommends balancing the turbine wheel and the compressor wheel each time the turbocharger is serviced. Balancing will ensure that no problems exist with either component.
Illustration 210 | g03677843 |
A turbine shaft on a component balancer |
Illustration 211 | g03677855 |
Compressor wheel in a component balancer |
Illustration 212 | g03677861 |
Boreless Compressor Wheel with Thrust Collar installed on Turbine Shaft for Balancing |
Illustration 213 | g03677876 |
Boreless Compressor Wheel with Thrust Collar installed on Turbine Shaft positioned onto the Balancer |
Turbochargers that are equipped with a boreless compressor wheel must be balanced with the compressor wheel, spacers (if used), and thrust collar installed onto the turbine shaft. The thrust collar should be installed to make up for any gaps on the turbine shaft if the compressor wheel was installed without the bearing. The gaps would cause the compressor wheel not to fit snug onto the turbine shaft and would cause problems when balancing.
Some factors that may cause a component to be unbalanced include the following items:
- Mechanical damage caused by foreign particles
- Uneven deposits of dirt
- Erosion of the blade edges on the components caused by the presence of solid particles in the intake air or exhaust gas
- Visible mechanical damage to the turbine shaft and/or compressor wheel
- When the turbine shaft and/or compressor wheel have been repaired/machined
- When a new compressor wheel is used on an salvaged/used turbine wheel shaft
Correcting Wheel Balance
Correcting the balance of the turbine and compressor wheel is sometimes needed especially after repairing any damaged areas on the wheels. Use 222-3074 Wheel Grinder with 174-8901 Cut Off Wheel or 4C-8513 Flap Wheel to remove material from the wheels. After checking the balance on the wheels, the following examples will show the correct and incorrect ways to rebalance a wheel. Use light pressure while correcting balance with the Grinder. No sharp edges are allowed.
Illustration 214 | g03736074 |
Factory balance location. |
Illustration 215 | g03736080 |
Factory balance location. |
Illustration 216 | g03736086 |
Factory balance location. |
Illustration 217 | g03736099 |
Factory balance location. |
Illustration 218 | g03736112 |
Factory balance location. |
Illustration 219 | g03736130 |
Factory balance location. |
Illustration 220 | g03736136 |
Factory balance location. |
Illustration 221 | g03736147 |
Acceptable grinding marks on the compressor wheel to correct balance. |
Illustration 222 | g03736159 |
Acceptable grinding marks on the compressor wheel to correct balance. |
Illustration 223 | g03736161 |
Acceptable grinding marks on the compressor nose to correct balance. |
Illustration 224 | g03736165 |
Acceptable grinding marks on the compressor nose to correct balance. |
Illustration 225 | g03736169 |
Acceptable grinding marks on the turbine nose to correct balance. |
Illustration 226 | g03736868 |
Acceptable grinding marks on the turbine wheel to correct balance. Grinding on the fins is acceptable as long as a light amount of material is removed. Never grind a compressor wheel fin. |
Illustration 227 | g03736873 |
This is unacceptable grinding for balance correction. The grinding is erratic and on the inboard portion of a compressor wheel. |
Illustration 228 | g03736897 |
This is unacceptable grinding for balance correction. Never cut the wheel to correct balance. No sharp edges are allowed. |
Illustration 229 | g03736917 |
This is unacceptable grinding for balance correction. Never make cuts on the vanes of the wheel. This wheel shows erratic grinding as well as too much material removed. |
Illustration 230 | g03736925 |
This is unacceptable grinding for balance correction. Never make cuts on the wheel. This wheel shows erratic grinding as well as a cut in the nose. |
Illustration 231 | g03736921 |
This is unacceptable grinding for balance correction. This wheel has been ground with excessive force causing hot spots on the wheel. |
Assembly Procedure
Due to the various turbocharger designs, the actual parts in your turbocharger assembly may vary. The following assembly techniques are basic procedures that apply to all turbochargers regardless of the design.
- The bearings are held in place with retaining rings at locations (Y). The bearings use a washer at location (X). Some turbochargers have bearings that are held in place with three retaining rings and some bearings are held in place with four retaining rings.
Turbochargers using THREE retaining rings should have the washers installed so that both washers face the turbine wheel, as shown in Illustration 232. Turbochargers using FOUR retaining rings should have the washers installed on the inside of the bearings, as shown in Illustration 233.
Show/hide tableIllustration 234 g03677902 Tooling 1P-1853 Retaining Ring Pliers.Show/hide tableIllustration 235 g06301764 The retaining rings have a rounded edge (1) on one surface and a rougher edge with a small lip (2) on the other surface. The small lip is caused when the retaining ring was punched out of sheet metal during manufacturing and can be felt with your fingertip. Make sure that the side of the retaining ring with the small lip faces AWAY from the bearing. - Use Tooling (A) to install the first retaining ring into the center housing. Make sure that the rounded edge of the retaining ring will be facing towards the bearing after the bearing is installed. Make sure that the gap in the retaining ring is aligned with the oil hole in the center housing.
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Illustration 236 g03677977 - Turn over the center housing. Apply clean engine oil to the bearing surface of the center housing.
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Illustration 237 g03678003 Show/hide tableIllustration 238 g06301765 - Apply clean engine oil to the washer and the bearing. Install the washer for the bearing, and then install bearing.
Note: Make sure that you are installing the correct sized bearings as determined in the inspection procedure. Also, apply clean engine oil to the bearing before installation.
Show/hide tableIllustration 239 g03678015 Show/hide tableIllustration 240 g06301764 - Use Tooling (A) to install the first retaining ring into the center housing. Ensure that the rounded edge of the retaining ring is towards the bearing after the bearing is installed. Ensure that the gap in the retaining ring is aligned with the oil hole in the center housing.
Note: The retaining rings have a rounded edge (1) on one surface and a rougher edge with a small lip (2) on the other surface. The small lip is caused when the retaining ring was punched out of sheet metal during manufacturing and can be felt with your fingertip. Make sure that the side of the retaining ring with the small lip faces AWAY from the bearing.
- Install the other bearing using the same basic procedure.
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Illustration 241 g03678019 Install the seal onto turbine shaft. Coat seal and turbine shaft with clean engine oil. Show/hide tableIllustration 242 g03678021 Turbine shaft installed into center housing - Install the seal onto the turbine shaft. Coat the seal and turbine shaft with clean engine oil and install the turbine shaft into the center housing.
- Turn the assembly over and place the end of the turbine shaft into a vise. Ensure that the housing spins freely on the turbine shaft. There should be no binding. If there is binding, remove the center housing and inspect for clearance issues.
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Illustration 243 g03678045 Inspecting the screen on the thrust plate. Lubricate the thrust plate before installing. Show/hide tableIllustration 244 g03678053 Thrust bearing installed - Ensure the screen located in the thrust plate is clean and free of obstructions. Install the thrust bearing, various washers, and spacers according to the turbocharger that is being serviced. Apply clean oil to all parts prior to installation.
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Illustration 245 g03678061 Lubrication port on the backing plate. - Apply clean engine oil to the lubrication hole of the backing plate, if equipped.
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Illustration 246 g03678065 Lubrication port on the backing plate. Show/hide tableIllustration 247 g06301767 Lubrication port on the center housing. - Install the backing plate. Ensure the oil hole located in the backing plate is aligned with the oil hole located in the center housing.
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Illustration 248 g03678077 Installing 6V-2055 Grease to the seals on the spacer - Apply 6V-2055 Grease to the grooves of the spacer and the seals for the compressor wheel side of the turbocharger. Install the seals into the spacer.
Note: The split in the seals should be located 180 degrees apart.
Show/hide tableIllustration 249 g03678080 Example of installing the spacer and the seals Show/hide tableIllustration 250 g03678086 Example of the spacer installation tool - Install the spacer by squeezing the seals together and pressing the spacer into the backing plate. A tool can be machined that aids the installation of the spacer and the seals. The tool should be a simple sleeve with the inner diameter tapered so the seals are compressed as the spacer is pushed through the sleeve.
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Illustration 251 g03678090 - Rotate the center section to be sure that the assembly spins smoothly without any binding.
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Illustration 252 g03737022 Using a press to seat the compressor wheel. Show/hide tableIllustration 253 g03678098 Torquing the nut - Install the compressor wheel onto the shaft. Lightly tap the compressor onto the shaft until the compressor wheel is fully seated. Apply 9S-3263 Thread Lock Compound to the threads of the turbine shaft. Tighten the nut to the correct specifications.
Refer to Table ? for the correct torque values.
Note: Do not use the nut to install the compressor wheel. Using the nut may result in galling of the compressor wheel from the nut turning against the surface.
Show/hide tableIllustration 254 g03678121 - Boreless compressor wheels should be threaded onto the turbine shaft and tightened until the compressor wheel bottoms out on the turbine shaft.
Refer to Table ? for the correct torque values.
Show/hide tableIllustration 255 g06301768 Cartridge installed into the turbine housing. - Install the cartridge assembly into the turbine housing, as shown.
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Illustration 256 g06300967 - Install the clamps and tighten. Tap the clamps with a hammer on all sides. Tighten the clamps again to the proper specifications. Repeat for the compressor housing.
Illustration 232 | g06301761 |
Turbocharger using THREE retaining rings |
Illustration 233 | g06301762 |
turbocharger using FOUR retaining rings |
Alternative Bearing Types
There are many turbocharger bearing systems. The two covered above are retained with snap rings. Two other common types are Multi Lobe Semi Floating (MLSF) bearings and a bearing with spacer system. Assembly of these two types of turbochargers is virtually the same as any other turbocharger once the cartridge is built up. This section will show some differences on these two types of bearing systems.
MLSF Bearing Type
The following section will describe the disassembly and assembly of turbochargers using the MLSF bearing type. This will be shown from the cartridge level. Housing removal is performed as any other turbocharger.
Illustration 257 | g03705253 |
- Place the cartridge assembly in a suitable vise using the flats of the turbine wheel to hold. Remove the compressor wheel (1).
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Illustration 258 g03705812 Show/hide tableIllustration 259 g03705312 The turbine shaft and wheel - Remove the four bolts (2) from back plate (3). Lift off the housing of the turbine wheel and shaft.
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Illustration 260 g03705278 - Remove the three screws (4).
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Illustration 261 g03705463 Show/hide tableIllustration 262 g03705284 - Remove collar (5) and thrust washer (6).
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Illustration 263 g03705300 - Remove bolt (7).
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Illustration 264 g03705373 Show/hide tableIllustration 265 g03705374 - Remove bearing (8).
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Illustration 266 g03705436 - Remove the seal ring (9) from the turbine shaft.
- Clean all the turbocharger parts thoroughly. Use methods mentioned within this document.
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Illustration 267 g03705436 - Install seal ring (9) onto the turbine shaft. Lightly lubricate the seal and the shaft with clean engine oil.
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Illustration 268 g03705448 - Install the bearing (8) into the housing. Ensure the bolt hole and the stake hole in the bearing line up.
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Illustration 269 g03705300 - Install bolt (7) and torque to
14 N·m (10.3 lb ft) to17 N·m (12.5 lb ft) .Show/hide tableIllustration 270 g03705462 Alignment of the oil holes is critical. Show/hide tableIllustration 271 g03705463 - Install the thrust washer (6) and the retaining collar (5). Be sure that the oil hole on the thrust washer (6) lines up with the oil hole on the housing.
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Illustration 272 g03705481 - Install three screws (4). Torque the screws (4) to specifications.
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Illustration 273 g03707609 - Install o-ring (10).
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Illustration 274 g03705540 - Place the turbine wheel and shaft back into the vise. Ensure that the seal ring and shaft are lightly lubricated with clean engine oil.
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Illustration 275 g03708183 - Install the turbine wheel and shaft into the housing. It may be necessary to rotate the turbine wheel and use downward pressure to get the seal ring to seat in the bore.
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Illustration 276 g03705812 - Install the backplate (3) using the four bolts (2). Torque the backplate (3) to specifications.
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Illustration 277 g03705253 - Install the compressor wheel (1). Torque the wheel to specifications
Bearing and Spacer System
- Place the cartridge assembly in a suitable vise using the flats of the turbine wheel to hold. Remove the compressor wheel (1).
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Illustration 279 g03705840 - Remove the four bolts (2) from backplate (3). Remove backplate (3) from the housing.
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Illustration 280 g03705853 - Remove three screws (4) from the thrust washer (5).
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Illustration 281 g03705859 Show/hide tableIllustration 282 g03705865 - Remove the thrust washer (5) and the retaining collar (6).
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Illustration 283 g03706107 - Remove the seal rings (7) from the retaining collar (6).
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Illustration 284 g03705870 Housing ready to be removed from the turbine shaft. Show/hide tableIllustration 285 g03705872 Housing removed from turbine shaft. - Lift the housing off the turbine shaft.
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Illustration 286 g03705875 Heat Shield. - Remove heat shield (8).
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Illustration 287 g03705876 Bearings and spacer Show/hide tableIllustration 288 g03705877 - Remove bearings (9) and the spacer (10).
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Illustration 289 g06301771 - Remove seal ring (11).
- Clean all the turbocharger parts thoroughly.
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Illustration 290 g03706034 - Install new seal ring (11). Lightly lubricate the shaft and the seal ring (11) with clean engine oil.
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Illustration 291 g03706040 - Place the housing in a suitable vise.
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Illustration 292 g03706042 - Install heat shield (8).
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Illustration 293 g03706201 - Install the turbine wheel and shaft assembly into the housing. It may be necessary to spin the wheel while pushing downward so that the shaft fully seats.
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Illustration 294 g03706048 - Rotate the housing in the vise so that the shaft is pointing up.
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Illustration 295 g03706054 Installing bearing Show/hide tableIllustration 296 g03706105 Installing spacer Show/hide tableIllustration 297 g03706054 Installing bearing - Install the bearings (9) and spacer (10) in the order shown above.
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Illustration 298 g03706262 - Install new seal rings (7) onto the retainer collar (6).
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Illustration 299 g03706274 Alignment of the oil holes is critical. Show/hide tableIllustration 300 g06301772 - Install thrust washer (5) and retainer collar (6). Be sure that the thrust washer (5) is orientated correctly with the oil supply hole in the housing.
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Illustration 301 g03706119 - Install three screws (4). Torque the screws to specifications
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Illustration 302 g03706177 - Install o-ring (12).
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Illustration 303 g03706179 - Install backplate (3) using four bolts (2). Torque the bolts to specifications
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Illustration 304 g03706183 - Install compressor wheel (1). Torque the wheel to specifications
Illustration 278 | g03705833 |
Specifications and Rebuilding Procedure for TPS-61, TPS-57, TPS-52, TPC-49, TPC-47, TPS-48, and TPS-44 Type ABB Turbochargers for 3500 Engines
Turbocharger and Turbocharger Component Weights
Use the following chart for weights of the turbocharger and its individual components.
Illustration 305 | g03550741 |
Turbocharger Component Weights | ||||||
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TPS 44 | TPS 48 | TPS 52 | TPS 57 | TPS 61 | ||
Turbocharger Weight | |
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Compressor Housing (1) | |
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Insert Wall (2) | |
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Diffuser (3) | |
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Cartridge Group (4) | |
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Turbine Casting with External Rupture Protection (5) | 1 Inlet | |
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2 Inlets | |
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3 Inlets | |
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4 Inlets | |
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Rupture Ring (6) | |
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Nozzle Ring (7) | |
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(1) | Does not include weight of any air cleaner piping or exhaust piping. |
Illustration 306 | g03549879 |
Breakdown of the Cartridge Group. |
Turbocharger Cartridge Component Weights | |||||
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TPS 44 | TPS 48 | TPS 52 | TPS 57 | TPS 61 | |
Cartridge Group (1) | |
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Compressor Wheel (2) | |
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Bearing Cover (3) | |
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Bearing Parts, Complete (4) | |
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Bearing Casing (5) | |
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Partition Wall (6) | |
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Shaft (7) | |
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Removing the Cartridge Assembly
Note: Refer to Table 21 and table 22 for the weight of the complete turbocharger and the individual turbocharger components.
Illustration 307 | g02138341 |
(1) Cartridge Group
(2) Diffuser
(3) Wall Insert
(4) Compressor Housing
(5) Nozzle Ring
(6) Rupture Ring
(7) Turbine Housing
- Position the turbocharger assembly onto a suitable work surface.
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Illustration 308 g02138413 Show/hide tableIllustration 309 g02138460 Using Tooling (A) - Attach a suitable lifting device to the compressor housing (4). Remove bolts (8) and rings (9). The compressor housing can now be separated from the cartridge assembly.
Note: Tooling (A) can be used to separate compressor housing (4) from the cartridge assembly, if necessary. Make sure that you apply equal force to each of side of the compressor housing with Tooling (A). This will allow the compressor housing to be removed evenly without damaging other components.
- Use a rubber mallet to tap wall insert (3) and remove wall insert (3) from the compressor housing. Bolts (8) can be installed into wall insert (3) to aid in removal of wall insert (3). Remove O-ring seal (10) and O-ring seal (11), if equipped.
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Illustration 310 g02139115 - Remove sensor (14). Attach a suitable lifting device to the cartridge group (1). Remove the nuts (13) and the rings (12) from the turbine housing and remove cartridge group (1).
Note: Tooling (A) can be used to separate the cartridge group (1) from the turbine housing, if necessary.
Show/hide tableIllustration 311 g02138616 - Remove nozzle ring (5) and sealing ring (15) from the turbine housing.
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Illustration 312 g02138633 - Use the suitable lifting device to place the cartridge assembly (1) onto Tooling (B). Remove screw (17) and remove diffuser (2). Remove O-ring seal (16).
Checking the Clearances of the Bearings
The clearances of the bearings should be measured before the cartridge assembly is disassembled. This will give a good indication of the bearing life that remains or any unusual wear problems. The turbine should be raised slightly before the axial clearance (A) is measured due to the weight of the turbine shaft.
Bearing Clearances | |||||||
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TPS 44 | TPC 47 | TPS 48 | TPC 49 | TPS 52 | TPS 57 | TPS 61 | |
A Minimum | |
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A Maximum | |
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B Minimum | |
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B Maximum | |
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Illustration 313 | g02138859 |
Measuring the axial clearance (A) and the radial clearance (B) of the bearings |
Disassemble the Cartridge Assembly
Illustration 314 | g06301775 |
Exploded view of the cartridge assembly |
- Use two opposing wrenches to remove compressor wheel (1), as shown.
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Illustration 316 g06301779 - Install a thread protector (6) over the threads of the turbine shaft and remove two screws (4). Install screws (4) into the tapped holes in bearing cover (3). Use screws (4) as forcing screws to remove bearing cover (3). Remove O-ring seal (2). Remove ring (5).
- Remove thread protector (6) and sealing disc (7).
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Illustration 317 g02138751 Removing the Turbine Shaft and Bearing Assembly - Remove bolts (13). Insert bolts (13) into the tapped holes of bearing assembly (12). Use bolts (13) as forcing screws to remove bearing assembly (12) from center housing (11).
Note: Make sure that you secure turbine shaft (8) before you remove bearing assembly (12).
- Pull turbine shaft (8) from the center housing and remove ring (9). Remove plate (10).
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Illustration 318 g02138752 Exploded View of the Bearing Assembly Show/hide tableIllustration 319 g02138818 - Separate bearing housings (24) and (14). Remove auxiliary bearing (21), thrust bearing (20), and thrust ring (19).
- Remove bolt (22) and remove bearing (23) from bearing housing (24).
- Remove retaining ring (18). Remove bolt (15) and bearing (17). Remove the other retaining ring (16) from bearing housing (14).
Illustration 315 | g06301778 |
Removing the Compressor Wheel |
Shaft Bearings
The following table lists guidelines for replacing the bearing. This guideline should only be used if the axial clearances and the radial clearances of the bearing were within specifications. Refer to "Checking the Clearances of the Bearings". If the clearances of the bearings were determined to be at the Maximum limits during inspection, the bearings should be replaced regardless of the condition to provide a good service life.
Bearing Inspection Guideline | ||
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Description | Observed Damage | Action |
Bearing Surfaces | Parts of Bearing Material Missing | Change Bearings |
Cracks in Bearing Material | Change Bearings | |
Scored Bearing Surfaces | Minor Scratches are Acceptable (1) | |
Surfaces are Worn, but in Good Condition | Use Bearing Again (2) | |
Pitting, Excessive Wear on Bearing Surface, Oil Starvation problem | Change Bearings |
(1) | NEVER attempt to remove scratches by polishing the bearing |
(2) | The Bearing MUST be within the specifications that are listed. Refer to "Checking the Clearances of the Bearings". |
Assembly Procedure
Illustration 320 | g06301790 |
Section view of what components get dry, oil, or Molykote applied to them during assembly |
Assembly Application Process for Components | ||
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Callout | Application Type | Description / Location |
(1) | Dry | Compressor Wheel - Sealing Disc |
(2) | Dry | Sealing Disc - Auxiliary Bearing |
(3) | Dry | Auxiliary Bearing - Thrust Ring |
(4) | Dry | Thrust Ring - Shaft |
(5) | Lightly Oiled | Radial Bearing, Outside and Inside diameter |
(6) | Lightly Oiled | Auxiliary Bearing - Axial Bearing |
(7) | Lightly Oiled | Compressor-end Bearing Flange - Bearing Casing |
(8) | Lightly Oiled | Turbine-end Bearing Flange - Bearing Casing |
(9) | Lightly Oiled | Axial Bearing - Thrust Ring |
(10) | Lightly Oiled | Compressor Wheel thread and Centering Seat |
(11) | Molykote | Auxiliary Bearing |
Assemble the Cartridge Assembly
Note: Refer to Table 21 and Table 22 for turbocharger component weights.
Torque Values for Cartridge Assembly | |||||
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TPS 44 | TPS 48 | TPS52 | TPS 57 | TPS 61 | |
(1) Compressor Wheel (1) | |
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(1) Compressor Wheel (2) | |
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(4) Bolt | |
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(13) Bolt | |
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(15) (22) Bolt | |
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(1) | Assembly Torque |
(2) | Check Loosening Torque |
- Install retaining ring (16) into bearing housing (14). Apply clean engine oil to bearing (17). Install bearing (17). Align the hole in bearing (17) with the hole in bearing housing (14) and install bolt (15). Then, install the other retaining ring (18). Tighten bolt (15).
Note: The retaining rings have a rounded edge (A) on one surface and one surface has a rougher edge with a small lip (B). The small lip is caused when the retaining ring was punched out of sheet metal during manufacturing and can be felt with your fingertip. Make sure that the side of the retaining ring with the small lip faces AWAY from the bearing.
- Apply clean engine oil to bearing (23) and thrust bearing (20). Install thrust ring (19) and thrust bearing (20). Install auxiliary bearing (21) and bearing housing (24). Install bearing (23). Install bolt (22). Tighten bolt (22).
Note: The oil hole in thrust bearing (20) must be aligned with the alignment pin in bearing housing (14).
Show/hide tableIllustration 325 g02138751 Installing the Turbine Shaft and Bearing Assembly - Install bearing assembly (12) into center housing (11) and install bolts (13). Tighten bolts (13). Apply 6V-2055 Grease to ring (9) and install ring (9) onto the shaft. Make sure that the ends of ring (9) are engaged.
- Apply clean engine oil to the turbine shaft (8). Position plate (10) onto center housing (11). Install turbine shaft (8) into center housing (11) and through the bearing assembly (12).
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Illustration 326 g03180618 - Install sealing disc (7). Install thread protector (6). Install O-ring seal (3) into bearing plate (3) and install bearing plate (3). Install bolts (4).
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Illustration 327 g06301778 Installing the Compressor Wheel - Tighten compressor wheel (1) to the proper torque. After torquing the compressor wheel try to loosen it with the "Check Loosening Torque" shown in Table 26. If the wheel loosens, then you must disassemble the cartridge group and clean all the axial contact surfaces and repeat the torque procedure. If the wheel does not loosen theretorquethe wheel to the proper assembly torque.
- Check the axial clearance and the radial clearance of the bearings. Refer to "Checking the Clearances of the Bearings".
Illustration 321 | g06301783 |
Illustration 322 | g06301784 |
Illustration 323 | g02138752 |
Exploded View of the Bearing Assembly |
Illustration 324 | g06301764 |
Note: Table 26 should be followed for proper torque values.
Installing the Cartridge Assembly
Torque Values for Installing the Cartridge | |||||
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TPS 44 | TPS 48 | TPS 52 | TPS 57 | TPS 61 | |
(8) Bolt | |
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(13) Nut | |
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(14) Sensor | |
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Illustration 328 | g02138341 |
(1) Cartridge Group
(2) Diffuser
(3) Wall Insert
(4) Compressor Housing
(5) Nozzle Ring
(6) Rupture Ring
(7) Turbine Housing
- Install sealing ring (15) into the turbine housing. Make sure that the sealing ring is layered correctly, as shown. Install nozzle ring (5)
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Illustration 330 g02138633 - Use the suitable lifting device to place the cartridge assembly (1) onto Tooling (B). Install O-ring seal (16).
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Illustration 331 g02139836 - Attach a suitable lifting device to the cartridge group (1). Position cartridge group (1) into the turbine housing. Install rings (12) and nuts (13) into the turbine housing. Install sensor (14). Tighten nuts (13).
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Illustration 332 g02139839 - Install O-ring seal (10) and O-ring seal (11), if equipped. Install wall insert (3) into compressor housing (4).
- Attach a suitable lifting device to the compressor housing (4). Position compressor housing (3) onto the cartridge assembly. Install rings (9) and bolts (8). Tighten bolts (8).
Illustration 329 | g02138616 |
Replacing, Checking, and Setting the Calibration of Turbocharger Wastegate Actuators
The following parts should be reused if possible, 337-4178 Hose, 258-4524 Sleeve, 161-6963 Clamp, and 161-6958 Hose Clip. If not possible replace with new.
Use the 215-2592 Wastegate Setting Kit to install the new wastegate actuator and calibrate the new wastegate actuator .
Illustration 333 | g03429947 |
(A) (B) (C) |
Removing and Installing the Wastegate Actuator
- Allow the turbocharger to cool.
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Illustration 334 g03490177 - Remove clip (1).
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Illustration 335 g03490217 - Remove nuts (2).
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Illustration 336 g03490237 - Remove the wastegate actuator. It will be necessary to pry the rod end from the turbocharger wastegate stud.
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Illustration 337 g03490243 - Measure the exposed threads (X). This will give a baseline for setting the new actuator.
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Illustration 338 g03491758 - Note the orientation of heat shield (3) and washer (4).
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Illustration 339 g03492128 - Install heat shield (3) onto the new actuator in the orientation noted in step 6.
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Illustration 340 g03492260 - Install washer (4).
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Illustration 341 g03492296 - Install jam nut (5). Adjust nut (5) to the length noted in step 5.
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Illustration 342 g03494101 - Install rod (6).
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Illustration 343 g03494156 - Install the built up actuator assembly onto the turbocharger. Torque nuts (2) to
12 ± 3 N·m (9 ± 2 lb ft) .Show/hide tableIllustration 344 g03494177 - Use tooling (A), (B, and) (C) to move rod (6).
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Illustration 345 g03494203 - Slip rod (6) over the wastegate stud. Install clip (1). The wastegate actuator is now ready for calibration.
Wastegate Actuator Specifications
Actuator Kit Part Number | Turbocharger Part Number | Pressure Specification |
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322-9352 | |
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384-1864 | |
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425-3709 | |
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425-3710 | |
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425-3712 | |
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425-3713 | |
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425-3714 | |
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425-3715 | |
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425-3716 | |
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439-1316 | |
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440-6689 | |
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440-6690 | |
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447-8004 | |
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447-8005 | |
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447-8006 | |
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447-8008 | |
Measuring and Adjusting Actuation Calibration Reading
- Allow the turbocharger to cool.
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Illustration 346 g03494537 - Install Indicator GP (D). The indicator can be mounted to a loose turbocharger as shown above or mounted to the engine. It may be necessary to use 6V-6042 Indicator Point to mount the Indicator (D).
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Illustration 347 g03494580 - Adjust the indicator (D) so that it is in-line with the actuator arm. This will ensure an accurate reading.
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Illustration 348 g03432078 - Remove hose (1) from the actuator (2).
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Illustration 349 g03495862 - Install hose (B) onto kit (A) by using clamp (C). Connect the opposite side of hose (B) onto actuator (2) by using clamp (C).
- Close the air pressure regulator on kit (A).
- Connect shop air to kit (A). Do not exceed the maximum inlet pressure for the regulator supplied in kit (A).
- Slowly open the regulator on kit (A). Observe the actuator (2) extending the shaft. Close the regulator. Observe the actuator (2) retracting the shaft. Repeat this cycle three times. This will ensure an accurate reading.
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Illustration 350 g03496057 Show/hide tableIllustration 351 g03432125 - Turn on the knob on the air pressure regulator kit (A) and slowly increase the air pressure while you observe the dial indicator (D). Increase the air pressure until the travel of the actuator rod (2) is
1 mm (0.039 inch) . Observe the pressure gauge and record the pressure reading. The actuator (2) should always travel1 mm (0.039 inch) when the actuator (2) is set to the specified pressure in Table 28 - Close the regulator.
- Adjust actuator (2) as needed.
- To increase the calibration setting, increase the preload on the actuator spring by screwing the rod end further toward the canister. Each half turn is an increase of
3.4 kPa (0.5 psi) . - To decrease the calibration setting, decrease the preload on the actuator spring by unscrewing the rod end further away from the canister. Each half turn is a decrease of
3.4 kPa (0.5 psi) .
- To increase the calibration setting, increase the preload on the actuator spring by screwing the rod end further toward the canister. Each half turn is an increase of
- Repeat step 8 through 11 until the actuator (2) is set to the spec in Table 28.
Thermal Spray Procedures for Turbocharger Compressor Housing Contour Bore
Illustration 352 | g02968782 |
Part Description
Base Metal | Cast Aluminum |
Hardness | N/A |
Flame Spray Equipment and Procedure
Maximum Surface Texture | |
Reason for Spraying | Foreign material damage or grooves in contour bore |
Mating Part Contact Area & Material | Controlled clearance |
Metco Equipment Type | 6P-II |
Metco Material | Metco 452 or 453 |
Finished Thickness | As required |
Finishing Allowance | |
Spray Angle | 90° to contour |
Substrate Pre-Heat Temperature | None |
Substrate Temperature During Spraying Not to Exceed | |
Auxiliary Cooling | Not required |
Rotation/Traverse Device | Lathe or turntable |
Rotation/Traverse Speed | |
Surface Preparation Method | Grit Blast |
Finishing Method | Machine or hand grind |
Grinding Equipment Type | Die grinder |
Recommended Wheel | Sanding arbor |
Machining Equipment Type | Tracer lathe |
Recommended Cutter Grade | 883 Carboloy or equivalent |
Flame Spray Process (6P) | Procedure |
Clean Part | Non-oil base solvent wash |
Undercut | Not required. If damage to contour bore is due to a deposit of compressor wheel material, the deposit must be removed with a hand grinder or scraper prior to oxide removal. |
Chamfer | Not required |
Remove oxide | Emery paper or glass beading |
Mask for blast | Use metal mask |
Blast Equipment | Suction cabinet |
Grit type and size | G-25 angular steel |
Blast air pressure | |
Blast nozzle to work distance | |
Mask for spray | Use metal mask |
Spray equipment type | 6PII |
Auxiliary cooling | Not required |
Nozzle | 6P7A-B - "B" nozzle - required 6P-600 siphon plug |
Air Capacity/pressure | 6P-3/Pinch air - |
Oxygen pressure | |
Oxygen flow | 34 |
Fuel gas pressure | |
Fuel gas flow | 34 |
Carrier gas pressure | |
Carrier gas flow | 37 |
Spray rate/bond pass | Not required. |
Spray rate/build up | 5 lbs. per hour - |
Gun to work distance | |
Rotation speed of part | |
Traverse rate of gun | |
Gun fixturing method | Hand held. |
Top coat/thickness | As required. |
Finishing equipment | Hand grinder. |
Part/cutter rotation | |
Traverse speed | |
Depth of rough cut | |
Depth of finish cut | |
If damage to contour bore is due to a deposit of compressor wheel material, the deposit must be removed with a hand grinder or scraper prior to oxide removal.
Thermal Spray Procedures for Turbocharger Compressor Housing Outlet Bore
Illustration 353 | g02981918 |
Part Description
Base Metal | Cast Aluminum |
Hardness | N/A |
Flame Spray Equipment and Procedure
Maximum Surface Texture | |
Reason for Spraying | Wear |
Mating Part Contact Area & Material | O-Ring |
Metco Equipment Type | 6P-II |
Metco Material | Metco452 or 453 |
Finished Thickness | As required |
Finishing Allowance | |
Spray Angle | 60° to bore |
Substrate Pre-Heat Temperature | None |
Substrate Temperature During Spraying Not to Exceed | |
Auxiliary Cooling | Not required |
Rotation/Traverse Device | Lathe or turntable |
Rotation/Traverse Speed | |
Surface Preparation Method | Grit Blast |
Finishing Method | Machine |
Machining Equipment Type | Milling machine |
Recommended Cutter Grade | 883 grade Carboloy or equivalent |
Method Replaced | Sleeving |
Remarks | - |
Flame Spray Process (6P) | Procedure | Check List |
Clean Part | Non-oil base solvent wash | |
Undercut | Not required | |
Chamfer | Not required | |
Remove oxide | Emery paper or glass beading | |
Mask for blast | Use rubber or metal mask | |
Blast Equipment | Suction cabinet | |
Grit type and size | G-25 angular steel | |
Blast air pressure | |
|
Blast nozzle to work distance | |
|
Mask for spray | Mask adjacent areas with Metco Masking Compound | |
Spray equipment type | 6PII | |
Auxiliary cooling | Not required | |
Nozzle | 6P7A-B - "B" nozzle - required 6P-600 siphon plug | |
Air Capacity/pressure | 6P-3/Pinch air - |
|
Oxygen pressure | |
|
Oxygen flow | 34 | |
Fuel gas pressure | |
|
Fuel gas flow | 34 | |
Carrier gas pressure | |
|
Carrier gas flow | 37 | |
Spray rate/bond pass | Not required | |
Spray rate/build up | 5 lbs. per hour - |
|
Gun to work distance | |
|
Rotation speed of part | |
|
Traverse rate of gun | |
|
Gun fixturing method | Hand held | |
Top coat/thickness | As required | |
Finishing equipment | Milling machine | |
Part/cutter rotation | |
|
Traverse speed | |
|
Depth of rough cut | |
|
Depth of finish cut | |
|
Additional finish method |
Thermal Spray Procedures for Turbocharger Exhaust Housing Outlet Bore
Illustration 354 | g02982081 |
Part Description
Base Metal | Cast Iron |
Hardness | N/A |
Flame Spray Equipment and Procedure
Maximum Surface Texture | |
Reason for Spraying | Wear, Erosion |
Mating Part Contact Area & Material | Metal expansion ring |
Metco Equipment Type | 6P-II |
Metco Material | 452 or 453 |
Metco Sealer | Not required |
Finished Thickness | As required |
Finishing Allowance | |
Spray Angle | 90° to bore |
Substrate Pre-Heat Temperature | |
Substrate Temperature During Spraying Not to Exceed | |
Auxiliary Cooling | METCO AJ, if required |
Rotation/Traverse Device | Lathe or turntable |
Rotation/Traverse Speed | |
Surface Preparation Method | Grit Blast |
Finishing Method | Machine |
Machining Equipment Type | Milling machine or lathe |
Recommended Cutter Grade | 883 grade Carboloy or equivalent |
Flame Spray Process (6P) | Procedure |
Clean part | Degrease in hot caustic solution |
Undercut | Not required |
Chamfer | All edges - 45° x |
Remove oxide | Use 60 grit emery paper or glass beading |
Mask for blast | Use metal mask |
Blast Equipment | Suction cabinet |
Grit type and size | G-25 angular steel |
Blast air pressure | |
Blast nozzle to work distance | |
Remove blast mask | Remove |
Mask for spray | Use METCO Anti-Bond or masking compound |
Spray equipment type | 6PII |
Auxiliary cooling | Not required |
Nozzle | 6P7C-K "K" nozzle |
Air capacity/pressure | 6P-3/Cooling air - |
Oxygen pressure | |
Oxygen flow | 42 |
Fuel gas pressure | |
Fuel gas flow | 50 |
Carrier gas pressure | |
Carrier gas flow | 37 |
Spray rate/build up | 12 lbs. per hour - |
Gun to work distance | |
Rotation speed of part | |
Traverse rate of gun | |
Gun fixturing method | Hand held |
Bond pass/thickness | |
Top coat/thickness | As required |
Finishing equipment | Lathe |
Part/cutter rotation | Not to exceed |
Traverse speed | |
Depth of rough cut | |
Depth of finish cut | |
Additional finish method | Emery polish if desired |
-Do not direct flame on area to be sprayed.
Thermal Spray Procedures for Bearing Diameter of Turbocharger Turbine Wheel and Shaft Assembly
Illustration 355 | g02982236 |
Part Description
Base Metal | Steel |
Hardness | N/A |
Flame Spray Equipment and Procedure
Maximum Surface Texture | |
Reason for Spraying | Wear, Bearing Failure |
Mating Part Contact Area & Material | Bearing |
Metco Equipment Type | 6P-II |
Metco Material | 447 or 453 |
Finished Thickness | As required |
Finishing Allowance | |
Spray Angle | 90° to part |
Substrate Pre-Heat Temperature | |
Substrate Temperature During Spraying Not to Exceed | |
Auxiliary Cooling | AJ |
Rotation/Traverse Device | Lathe |
Rotation/Traverse Speed | |
Surface Preparation Method | Grit Blast |
Finishing Method | Grind |
Grinding Equipment Type | Cylindrical or tool post |
Recommended Wheel | 46J or 46K silicon carbide |
Flame Spray Process (6P) | Procedure | Check List |
Clean part | Metco Cleaning Solvent | |
Undercut | Not required | |
Chamfer | Edges 45° x |
|
Remove oxide | Emery paper - 60 grit | |
Mask for blast | Use metal mask or duct tape | |
Blast equipment | Suction cabinet | |
Grit type and size | METCOLITE "C" Aluminum Oxide | |
Blast air pressure | |
|
Blast nozzle to work distance | |
|
Remove blast mask | Remove | |
Mask for spray | Use metal mask/METCO Anti-Bond | |
Spray equipment type | 6PII | |
Auxiliary cooling | METCO AJ | |
Nozzle | 6P7C-N "N" Concentrating Nozzle | |
Air capacity/pressure | 6P-3/Cool - |
|
Oxygen pressure | |
|
Oxygen flow | 45 | |
Fuel gas pressure | |
|
Fuel gas flow | 55 | |
Carrier gas pressure | |
|
Carrier gas flow | 37 | |
Spray rate/build up | 5 lbs. per hour - |
|
Gun to work distance | 447 - |
|
Rotation speed of part | |
|
Traverse rate of gun | |
|
Gun fixturing method | Hand held. | |
Top coat/thickness | As required. | |
Finishing equipment | Cylindrical or tool post grinder. | |
Depth of rough cut | Plunge to |
|
Depth of finish cut | Dress if necessary - plunge to finish size. | |
Additional finish method | Polish with 400 grit emery if necessary. |
- CAUTION: Temperature in excess of
- Do not allow grinding wheel to load.
- Do not direct flame or area to be sprayed.
Thermal Spray Procedures for Turbocharger Outlet Adapter on 3500 Engines
Illustration 356 | g03083716 |
3500 Engine - Turbocharger Outlet Adapter | |||
---|---|---|---|
Model | (A) | (B) | (C) |
3508, 3508B, 3512, 3516, 3516B | |
|
|
Part Description
Base Metal | Aluminum Casting |
Hardness | - |
Arc Spray Equipment and Procedure
Maximum Surface Texture | |
Reason for Spraying | Fretting and wear |
Mating Part Contact Area & Material | Aluminum Pipe |
Arc Spray Equipment Type | SmartArc by Oerlikon Metco,TAFA 8830 MHU, or TAFA 8835 MHU |
Wire | TAFA 75B Wire |
Finish Thickness | As Required |
Finishing Allowance | |
Spray Angle | 90° |
Substrate Pre-Heat Temperature | |
Substrate Temperature During Spraying Not to Exceed | |
Auxiliary Cooling | If desired |
Rotation/Traverse Speed | |
Surface Preparation Method | Undercut and Grit blast |
Machining Method | Machine |
Equipment Required | Horizontal or vertical boring machine |
Recommended Cutting Tool | ISCAR DNMG 432TFIC507 |
Blast Media Recommendation | Pressure Type Only (Aluminum Oxide Grit) |
Arc Spray | Procedure | Check List | ||
Clean Part | Degrease | |||
Undercut | To "tru-up" surface | |||
Remove Oxide | Use emery cloth or glass bead blaster | |||
Clean Spray Area | Commercial degreaser | |||
Mask for Grit Blast | Duct Tape, metal shield, or rubber | |||
Grit Blast Equipment | Pressure type only | |||
Grit Type and Size | 20 mesh aluminum oxide | |||
Blast Air Pressure | |
|||
Blast Nozzle to Work Distance | |
|||
Remove Blast Mask | Make sure that surface is clean | |||
Mask for Metal Spray | AntiBond or Blue Layout Dye | |||
Metal Spray Equipment Type | Smart Arc by Oerlikon Metco | TAFA | ||
Consumable (Bondcoat) | TAFA 75B | TAFA 75B | ||
Clamp Pressure | |
|||
Air Jets/Pressure | |
|
||
Arc Load Volts | 30V | 30V | ||
Amps | 125 Amps | 150 Amps | ||
Gun to Work Distance (Standoff) | |
|
||
Spray Rate/Bond Pass | |
|
||
Rotation Speed Of Part (RPM) | RPM varies depending on diameter | |||
Rotation Speed Of Part | |
|||
Traverse Rate of Gun | |
|||
Gun Fixturing Method | Machine mount or hand held | |||
Finishing Equipment | Horizontal or vertical boring machine | |||
Part/Cutter Rotation (Roughing) | |
|||
Part/Cutter Rotation (Finishing) | |
|||
Coolant | Oil based synthetic - 40:1 ratio | |||
Traverse Speed | |
|||
Depth of Rough Cut | |
|||
Depth of Finish Cut | |
Flame Spray Equipment and Procedure
Maximum Surface Texture | |
Reason for Spraying | Fretting and wear |
Mating Part Contact Area & Material | Aluminum Pipe |
Oerlikon Metco Equipment Type | 6P-II by Oerlikon Metco |
Oerlikon Metco Material | Metco 471 NS |
Finish Thickness | As Required |
Finishing Allowance | |
Spray Angle | 90° |
Substrate Pre-Heat Temperature | None |
Substrate Temperature During Spraying Not to Exceed | |
Auxiliary Cooling | If desired |
Rotation/Traverse Speed | |
Surface Preparation Method | Undercut and Grit blast |
Finishing Method | Machine |
Machining Equipment Type | Horizontal or vertical boring machine |
Recommended Cutter Grade | C-2, 883 Carboloy, or equivalent |
Flame Spray Process (6P-II) | Procedure | Check List |
Clean Part | Degrease in hot aluminum safe cleaner | |
Undercut | To "tru-up" surface | |
Remove Oxide | Use emery cloth or glass bead blaster | |
Clean Spray Area | Metco cleaning solvent or equivalent | |
Mask for Grit Blast | Duct Tape, metal shield, or rubber | |
Grit Blast Equipment | Pressure type only | |
Grit Type and Size | Metcolite "C" or equivalent | |
Blast Air Pressure | |
|
Blast Nozzle to Work Distance | |
|
Remove Blast Mask | Remove mask, make sure that surface is clean | |
Mask for Metal Spray | Metco AntiBond or Blue Layout Dye | |
Metal Spray Equipment Type | 6P-II Hand Held Thermo Spray System by Oerlikon Metco | |
Auxiliary Cooling | AJ siphon unit, If desired | |
Nozzle | 6P-C7-D "D" Nozzle | |
Air Capacity/Pressure | 6P-3/Cooling Air |
|
Oxygen Pressure | |
|
Oxygen Flow | |
|
Fuel Gas Pressure | |
|
Fuel Gas Flow | |
|
Carrier Gas Pressure | |
|
Carrier Gas Flow | |
|
Spray Rate/Build Up | |
|
Gun to Work Distance | |
|
Traverse Rate of Gun | |
|
Gun Fixturing Method | Machine mount or hand held | |
Top Coat/Thickness | |
|
Finishing Equipment | Horizontal or vertical boring machine | |
Part/Cutter Rotation | |
|
Traverse Speed | |
|
Depth of Rough Cut | |
|
Depth of Finish Cut | |
|
Additional Finish Method | Emery cloth for desired finish |
Storage Procedures
Proper protection of the turbo from corrosion is important. Corrosion will start in as little as one hour after the turbo has been cleaned.
When the turbo will not be inspected for one hour or less the turbo should be coated with a rust or corrosion inhibitor or coated with clean engine oil. The turbo should be individually wrapped to prevent contamination, and should be stored in a protected area to avoid damage. See Illustration 357.
When the turbo will not be inspected in two days or more the turbo should be coated with a rust or corrosion inhibitor or coated with clean engine oil and should be placed in a container which is clean and structurally solid. The container should be covered or wrapped in plastic to prevent damage and contamination to the turbo. See Illustration 358.
Refer to SEHS9031Special Instruction, "Storage Procedure for Caterpillar Products" for more information.
Illustration 357 | g06278538 |
Example of protection for a component that is stored for a shorter term |
Illustration 358 | g06278539 |
Example of protection for a component that is stored for a longer period |