Usage:
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At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Drain the coolant only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap from the radiator slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to avoid personal injury. |
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1. Drain the coolant from the cooling system.
2. Remove step plates (1) from the turbochargers.
3. Loosen clamp (2), move the rubber connector off of the turbocharger.
4. Remove the shield assemblies from elbow (3). Attach a hoist to elbow (3). Remove the bolts holding elbow (3). Remove elbow (3), the springs and the ring seals. The weight of the elbow is approximately 55 kg (120 lb).
5. Loosen clamps (4) and (5). Move the rubber connector and the exhaust piping off of the turbocharger.
NOTE: It may be necessary to remove the exhaust piping held by clamp (5) completely. If removed, use a hoist. If not removed, tie up in place.
6. Disconnect two oil drain lines (6) from the turbochargers.
7. Remove all of the bolts that hold tube assembly (7) to the turbocharger support group.
NOTE: There is also a clip and bolt on tube assembly (7) at the flywheel end of the turbocharger support group. Remove these also. Remove tube assembly (7).
8. Remove two tube assemblies (8) and the mounting clips.
9. Disconnect two oil drain lines (9) from the turbochargers.
10. Remove eight bolts (10)[four on each side].
11. Remove tube (11).
12. Disconnect two tube assemblies (12) from the regulator housing. Remove the tube assemblies.
13. Remove the bolts and washers that hold two pipes (13) in the aftercooler housings.
14. Mark wires (14) for identification. Disconnect from tube assembly (16).
15. Remove the mounting bolts and tube assembly (16).
16. Remove eight bolts (15) that connect the turbocharger support group to the auxiliary drive.
17. Attach a hoist to the turbocharger support group in a manner that the unit will be held level. Remove twelve bolts (18).
| NOTICE |
|---|
Do not remove four bolts (17) that hold bracket (19) to the side rails. |
18. Remove the support group and all turbochargers as a unit. The weight of the unit is approximately 475 kg (1045 lb).
NOTE: The following steps are for the installation of all turbochargers and the support group.
19. Put the gaskets in place for the oil drain lines on the drain lines and the exhaust manifolds. Tie in place with tag wire.
20. Use a hoist to install the turbocharger support group and the turbochargers as a unit.
21. Install twelve bolts (18).
22. Install eight bolts (15) that connect the turbocharger support group to the auxiliary drive.
23. Use new O-ring seals. Install the mounting bolts and tube assembly (16).
24. Identify and connect wires (14) to tube assembly (16).
25. Install new O-ring seals. Install the bolts and washers that hold two pipes (13) in the aftercooler housings.
26. Install tube (11).
27. Install the O-ring seals. Connect two tube assemblies (12) to the regulator housing.
28. Be sure the gaskets are in place. Connect two oil drain lines (9) to the turbochargers.
29. Be sure the gaskets are in place. Apply 5P3931 Anti-Seize Compound to the bolts and washers. Install eight bolts (10).
30. Install tube assembly (7). Install the bolts that hold tube assembly (7) to the turbocharger support group.
31. Use new O-ring seals. Install two tube assemblies (8) and the mounting clips.
32. Be sure the gaskets are in place. Connect two oil drain lines (6) to the turbochargers.
33. Be sure the springs and the ring seals are in place. Apply 5P3931 Anti-Seize Compound to the bolts and washers. Attach a hoist to elbow (3). Install elbow (3). Install the shield assemblies to elbow (3).
34. Move the rubber connector and the exhaust piping in position on the turbocharger. Tighten clamps (4) and (5).
NOTE: It may be necessary to install the exhaust piping held by clamp (5), completely. If required, use a hoist.
35. Move the rubber connector in position on the turbocharger. Tighten clamps (2).
36. Install step plates (1) to the turbocharger.
37. Fill the cooling system with coolant to the proper level. Refer to the Operation & Maintenance manual for this operation.
Remove & Install Turbochargers (Low Pressure)
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At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Drain the coolant only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap from the radiator slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to avoid personal injury. |
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1. Drain the coolant from the cooling system.
2. Remove step plates (1) as required.
| NOTICE |
|---|
It may be necessary to tie up (or remove) the exhaust pipe held by clamp (3) when the turbocharger is removed. If removed, use a hoist. |
3. Loosen clamps (2) and (3) as required.
NOTE: The procedure for removing both low pressure turbochargers is the same. Only one is shown.
4. Remove four bolts and washers (4). Remove the O-ring seal when turbocharger is removed.
5. Disconnect both ends and remove line (6). Remove the O-ring seals.
6. Remove the bolts to disconnect drain line (5). Remove the gasket.
7. Disconnect and remove line (7) from the turbocharger. Remove the O-ring seals.
8. Disconnect both ends and remove line (10). Remove the O-ring seals.
9. Attach a hoist to the turbocharger.
10. Remove eight bolts and washers (8). Remove the O-ring seal when the turbo is removed.
11. Remove four bolts, spacers and locknuts (9).
12. Remove adapter (11) from the turbocharger. Remove the O-ring seal.
13. Disconnect line (12) from the turbocharger. Remove the O-ring seal.
14. Remove the bottom mounting bolts. Remove the turbocharger. The weight of the turbocharger is 95 kg (210 lb).
NOTE: The following steps are for installing the low pressure turbocharger.
15. Install the turbocharger. The weight of the turbocharger is 95 kg (210 lb). Apply 5P3931 Anti-Seize Compound to the bolts and washers. Install the bottom mounting bolts.
16. Install the O-ring seal. Connect line (12) to the turbocharger.
17. Install the O-ring seal and adapter (11).
18. Install the O-ring seal. Connect line (7) to the turbocharger.
19. Install the O-ring seals on line (10). Install line (10) and any clips.
20. Install the O-ring seal. Install eight bolts and washers (8).
21. Apply 5P3931 Anti-Seize Compound to the bolts, spacers and locknuts. Install four bolts, spacers and locknuts (9).
22. Install the O-ring seal. Install four bolts and washers (4).
23. Install the O-ring seals on line (6). Install line (6).
24. Install the gasket. Install the bolts to connect drain line (5).
25. Install exhaust pipes (2) or (3) (as required) to the engine compartment. Use a hoist. Tighten the clamps.
26. Install step plates (1) as required.
27. Fill the cooling system with coolant to the correct level. Refer to the Operation & Maintenance manual for this information.
Remove & Install Turbochargers (High Pressure)
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At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Drain the coolant only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap from the radiator slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to avoid personal injury. |
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1. Drain the coolant from the cooling system.
2. Remove the step plate from the turbocharger.
NOTE: The procedure for removing the high pressure turbochargers is the same for both. Only one is shown.
3. Remove six bolts and washers (3). Remove side bracket (2) and the spacers.
4. Remove oil supply line (1). Remove the O-ring seals.
5. Disconnect oil drain line (5). Remove the gasket when the turbocharger is removed.
6. Remove four bolts (6).
7. Attach a hoist to the turbocharger.
8. Remove four bolts (4).
9. Remove eight bolts (7).
Exhaust Bypass (waste gate) side view.
10. If the turbocharger on the exhaust bypass (waste gate) side is being removed:
a. Disconnect tube assemblies (10) and (11).
b. Remove tube assembly (9).
c. Remove four bolts (8).
d. Remove four nuts (12) and the exhaust bypass valve from the turbocharger. Remove the gasket.
11. Remove the turbocharger. The weight of the turbocharger is 32 kg (70 lb).
NOTE: The following steps are for the installation of the high pressure turbocharger.
12. Install the turbocharger in the reverse order of removal.
13. If the turbocharger on the exhaust bypass (waste gate) side is being installed:
a. Install the gasket, exhaust bypass valve and four nuts (12) to the turbocharger.
b. Install the O-ring seals. Connect lines (10) and (11).
c. Install the O-ring seals. Install tube assembly (9).
d. Apply 5P3931 Anti-Seize Compound to the bolts and washers. Install four bolts (8).
14. Apply 5P3931 Anti-Seize Compound to the bolts. Install eight bolts (7).
15. Apply 5P3931 Anti-Seize Compound to the bolts and washers. Install side bracket (2) and the spacers. Install six bolts and washers (3).
16. Install the O-ring seals. Install oil supply line (1).
17. Install the gasket. Connect oil drain line (5).
18. Install four bolts (6).
19. Apply 5P3931 Anti-Seize Compound to the bolts and washers. Install four bolts (4).
20. Install the step plate.
21. Fill the cooling system with coolant to the correct level. Refer to the Operation & Maintenance manual for this information.
Disassemble & Assemble Turbocharger (Low Pressure)
Start By:
a. remove turbocharger
1. Put the turbocharger in position on a suitable holding fixture.
2. Put marks on the housings of the turbocharger for correct installation and alignment at assembly.
3. Loosen the lock tabs, remove eight bolts with locks (3) and four clamps (2). Remove turbine housing (1) from cartridge group (6).
4. Remove eight bolts and lockwashers (5) with the four clamps. Remove the cartridge assembly from compressor housing (4).
| NOTICE |
|---|
To prevent a bent shaft, do not put a side force on the turbine shaft when the compressor wheel nut is loosened. |
5. Put the cartridge assembly in a holding fixture in a vertical position. Use a universal joint and socket of the correct size to remove nut (7) and washer (8) that holds compressor wheel (27) on the turbine shaft.
6. Use a press and push turbine shaft (17) out of compressor wheel (27) and the cartridge housing. Remove compressor wheel (27) from the cartridge housing.
7. Remove shroud (16) from turbine shaft (17).
8. Remove seal ring (18) from turbine shaft (17).
9. Remove ring (9). Remove seal-ring (26) from ring (9).
10. Remove retaining ring (12) and cover (11). Remove O-ring seal (23) from cover (11).
11. Remove shield (10).
12. Remove ring (25).
13. Remove three bolts and lockwashers (13).
14. Remove retainer (24). Make a note of the position of the oil holes for correct alignment at assembly.
15. Remove bearing (22). Make a note of the position of the oil holes for correct alignment at assembly.
16. Remove ring (21).
17. Remove pipe plug (19) from bearing housing (14).
18. Remove two bolt assemblies (20) from the bearing housing.
19. Remove two bearings (15) from the bearing housing.
NOTE: If the bearings are to be used again, put identification on them, as to their location, for correct assembly.
NOTE: The following steps are for the assembly of the turbocharger.
NOTE: For additional information also see the Specifications Manual for 3512 And 3516 EUI Engines, Form no. SENR5595.
20. Make sure all of the oil passages in the turbocharger cartridge housing, backplate assembly and bearings are clean and free of dirt and foreign material.
21. Put clean engine oil on all parts of the cartridge at assembly.
22. Install two bearings (15) in the bearing housing in their original locations.
23. Install two bolt assemblies (20) to the bearing housing. Use 9S3265 Retaining Compound on bolt assemblies.
24. Install pipe plug (19) to bearing housing (14).
25. Install shroud (16) to turbine shaft (17).
26. Install seal ring (18).
27. Use a press and push turbine shaft (17) in bearing housing (14).
28. Install ring (21).
29. Install bearing (22). Position the oil holes for correct alignment.
30. Install retainer (24). Position the oil holes for correct alignment.
31. Install three lockwashers and bolts (13).
32. Install shield (10).
33. Install O-ring seal (23) to cover (11).)
34. Install cover (11) and retaining ring (12).
35. Install O-ring seal (26) to ring (9).
36. Install O-ring seal (25).
37. Install compressor wheel (27) to turbine shaft (17).
| NOTICE |
|---|
To prevent a bent shaft, do not put a side force on the turbine shaft when the compressor wheel nut is loosened. |
38. Install washer (8) and nut (7). Tighten to 120 ± 5 N·m (88 ± 4 lb ft).
39. Put the turbocharger in position on a suitable holding fixture.
40. Align the marks on the housings of the turbocharger for correct installation.
41. Install eight bolts with locks (3) and four clamps (2). Install turbine housing (1) to cartridge group (6).
NOTE: Do not bend locks (3) until the turbocharger is installed to the engine.
42. Install eight bolts and lockwashers (5) with the four clamps. Install the cartridge assembly to compressor housing (4).
End By:
a. install turbocharger
Disassemble Turbocharger (High Pressure)
Start By:
a. remove turbocharger
Typical Example.
1. Put the turbocharger in position on a suitable holding fixture.
2. Put marks on the housings of the turbocharger for correct installation and alignment at assembly.
3. Loosen clamp (2) and remove compressor housing (3) and clamp (2) from the cartridge assembly.
Typical Example.
4. Remove the bolts and clamps (4). Remove cartridge assembly (5) from turbine housing (6).
| NOTICE |
|---|
To prevent a bent shaft, do not put a side force on the turbine shaft when the compressor wheel nut is loosened. |
5. Put the end of the turbine shaft in a suitable holding fixture. Use a universal joint and socket of the correct size to remove the nut that holds compressor wheel (7) on the turbine shaft.
6. Use a press and push the turbine shaft out of compressor wheel (7) and the cartridge housing. Remove compressor wheel (7) from the cartridge housing.
7. Remove shroud (9) from turbine shaft (8).
8. Remove piston ring (10) from turbine shaft (8).
9. Remove four bolts (11).
10. Remove backplate assembly (12) from the cartridge housing. Make a note of the position of the oil holes in the backplate assembly and cartridge housing for correct alignment at assembly.
11. Push spacer (13) out of the bore in backplate (12).
12. Remove seal rings (14) from spacer (13).
13. Remove seal (15) from the cartridge housing.
14. Remove thrust collar (16) from the cartridge housing.
15. Remove thrust bearing (17) from the cartridge housing.
NOTE: If the bearings are to be used again, put identification on them, as to their location, for correct assembly.
16. Remove bearing (18) from the cartridge housing.
17. Remove washer (19) from the cartridge housing.
18. Remove snap rings (20) and (21).
19. Remove bearing (22) from the cartridge housing.
20. Remove washer (23) from the cartridge housing.
21. Remove snap ring (24) from the cartridge housing.
Assemble High Pressure Turbocharger
NOTE: For additional information also see the Specifications Manual for 3512 And 3516 EUI Engines, Form no. SENR5595.
1. Make sure all of the oil passages in the turbocharger cartridge housing, backplate assembly and bearings are clean and free of dirt and foreign material.
2. Put clean engine oil on all parts of the cartridge at assembly.
NOTE: Make sure the round edge on the outside diameter of the snap ring is toward the bearing when the snap rings are installed.
3. Install snap ring (24) in the turbine end of the cartridge housing. Install washer (23) and bearing (22).
4. Install snap ring (21) in the cartridge housing to hold the washer and bearing in place.
5. Install snap ring (20) in the cartridge housing.
6. Install washer (19) and bearing (18) in the cartridge housing until washer (19) makes contact with snap ring (20).
7. Install thrust bearing (17) over the dowels in the cartridge housing. Make sure the grooves in bearing (17) are toward the outside as shown.
8. Put thrust collar (16) in position on the thrust bearing with the counterbore for the spacer up.
9. Install seal ring (15) in the groove of the cartridge housing.
10. Install seal rings (14) on spacer (13) so the gaps in the seal rings are 180° apart.
11. Install spacer (13) in backplate assembly (12).
12. Make sure the oil passage in the cartridge housing and the oil passage in the backplate assembly are in alignment. Put backplate assembly (12) in position on the cartridge housing. Make sure the spacer fits correctly in the counterbore of the thrust collar.
13. Install the bolts to hold backplate assembly (12) to the cartridge housing. Tighten the bolts to a torque of 39 ± 2 N·m (29 ± 1 lb ft).
14. Put turbine shaft (8) in position in a suitable holding fixture. Put 6V2055 High Vacuum Grease in the groove for seal ring (10). Make sure the grease fills the groove approximately one half or more of the groove depth for the complete circumference of the groove to help make a carbon dam under the seal ring. Install seal ring on turbine shaft.
15. Install shroud (9) on turbine shaft (8).
16. Install the cartridge housing on the turbine shaft while the spacer in the backplate is held in position. Make sure the seal ring on the turbine shaft is fitted correctly in the cartridge housing.
17. Put compressor wheel (7) in position on the turbine shaft.
| NOTICE |
|---|
Do not put a side force on the turbine shaft when the nut is tightened or a bent shaft will be the result. |
18. Install the nut for compressor wheel (7) as follows:
a. Put a small amount of 2P2506 Thread Lubricant on the threads and contacting surfaces of the nut and compressor wheel (7)
b. Install the nut onto the shaft and compressor wheel (7). Tighten the nut to 31 ± 2 N·m (23 ± 1 lb ft).
| NOTICE |
|---|
Do not bend or add stress to the shaft when the nut is loosened or tightened. |
c. Remove the nut. Put 6V1541 Quick Cure Primer on the threads of the nut and the contacting surfaces of compressor wheel (7) and the shaft. Wipe the components clean.
d. Put 9S3265 Retaining Compound on the threads of the shaft and nut.
e. Install the nut on the shaft and compressor wheel (7). Tighten the nut to a torque of 5 ± 2 N·m (48 ± 10 lb in).
f. Tighten the nut holding compressor wheel (7) an additional 135 ± 5°.
Typical Example
19. Put the cartridge assembly in position in turbine housing (6). Make sure the marks on the turbine housing and cartridge are in alignment. Install turbine housing (6) on a suitable holding fixture. Install two clamps (4) and eight bolts.
Typical Example.
20. Put clamp (2) and compressor housing (3) on the cartridge assembly.
Put 5P3931 Anti-Seize Compound on the threads of the clamp. Move clamp (2) in its correct position and tighten the clamp to a torque of 14 ± 1.5 N·m (10 ± 1 lb ft). Hit the clamp lightly all around and tighten the clamp again to a torque of 14 ± 1.5 N·m (10 ± 1 lb ft).
End By:
a. install turbocharger