D348 INDUSTRIAL & MARINE ENGINES Caterpillar

start by:

a) remove air cleaner

b) remove heat shield (marine only)

1. Remove bolt (1) and washer (2).

2. Loosen bolts (3), (4) and (6) to loosen tube (5).

3. Remove oil inlet and outlet lines (7) from the turbocharger.

4. Remove four bolts (8) and nuts. Remove turbocharger (9), gasket and the coupling.

Install Turbocharger

1. Install new O-ring seals (2) and put clean engine oil on the O-ring seals. Be sure the seal rings are not damaged on coupling (1) and put the coupling in position.

2. Put the turbocharger in position with a new gasket (3).

3. Put 5P3931 Anti-Seize Compound on the threads of the bolts and nuts that hold the turbocharger to the elbow. Tighten the nuts to a torque of 40 ± 4 lb.ft. (55 ± 5 N·m).

4. Tighten bolts (4), (6) and (7) that hold elbow (5).

5. Install oil inlet and outlet lines (8) on the turbocharger.

6. Install washer (10) and bolt (9).

a) install heat shield (marine only)

b) install air cleaner

Disassemble Turbochargers

start by:

a) remove turbocharger

1. Put turbocharger in position on tool group (A). Put a mark on cover (1), cartridge (3) and housing (2) for correct alignment and installation at assembly.

2. Remove twelve bolts (4) and six clamps.

3. Remove O-ring seal (5) from the cover.

4. Bend back locks (6) and remove bolts (7). Remove cartridge assembly (3) from the turbine housing.

5. Put the cartridge assembly (3) in position on tool (B).

6. Remove the nut that holds compressor wheel (8) in position.

7. Put the cartridge assembly in position in a press. Remove compressor wheel and shaft from the cartridge.

8. Remove shroud (9) and ring from the shaft. Use the 5P6518 Reusability Fixture Group to check the shaft to make sure it is straight. Complete instructions and parts specifications are given in special instruction form SMHS6998.

9. Remove spacer (10) from the cartridge assembly.

10. Remove the two rings (11) from the spacer.

11. Bend back locks (14). Remove bolts (13) and plate assembly (12).

12. Remove O-ring seal (15) from the plate.

13. Start from top and remove collar bearing, bearing and ring. Use tool (C) to remove snap ring.

14. Turn cartridge housing over. Start from top and use tool (C) to remove snap ring. Remove ring and bearing. Use tool (C) to remove snap ring.

Assemble Turbochargers

1. Clean and inspect all parts. Make a replacement of the parts that are worn or damaged. See SPECIAL INSTRUCTION Form No. SMHS6854 for TURBOCHARGER RECONDITIONING. Also see GUIDELINE FOR REUSEABLE PARTS Form No. SEBF8018.

2. Install snap ring (1) in cartridge housing with tool (A).

3. Install bearing (2) in cartridge housing.

4. Install ring (3) in cartridge housing.

5. Install snap ring (4) in cartridge housing with tool (A).

6. Turn the cartridge housing over. Install snap ring (5) in housing with tool (A).

7. Install ring (7) and bearing (6) in the cartridge housing.

8. Install thrust bearing (8) in the cartridge housing. Make sure the grooves in bearing (8) are toward the outside as shown.

9. Put thrust collar (9) in position on the thrust bearing with the counterbore for the spacer up.

10. Install O-ring seal (10) on the plate assembly.

11. Install the plate assembly (11) in the cartridge housing.

12. Install the locks (13) and bolts (12) that hold plate assembly to the cartridge housing. Tighten the bolts to a torque of 35 ± 5 lb.in. (4.0 ± 0.6 N·m). Bend the tabs of the locks on the bolts.

13. Install the seal rings (15) on spacer (14) so the gaps in the rings are 180° apart.

14. Install spacer (16) in the plate assembly.

15. Put the wheel (18) and shaft on tooling (B). Put 6V2055 High Vacuum Grease in the groove for seal ring (19). 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 (19) and shroud (17) on the shaft.

16. Install cartridge assembly (20) on the wheel and shaft assembly. Make sure the seal ring on the turbine shaft is fitted correctly in the cartridge housing.

17. Put a small amount of oil on the turbine shaft threads and the compressor wheel face that will be under the nut. Install the nut and tighten to a torque of 150 lb.in. (17 N·m) to push the wheel on the shaft.

18. Loosen the nut and tighten it again to a torque of 30 lb.in. (3.4 N·m). Tighten the nut 90° of a turn more.

19. Put the cartridge housing in a vise as shown. Check the shaft end play with tool group (C). The shaft end play must be .003 to .010 in. (0.076 to 0.254 mm).

20. Install turbine housing (21) on tool group (D) as shown. Put the cartridge assembly (20) in position in housing (21). Make sure the marks on the housing and cartridge are in alignment.

21. Put 5P3931 Anti-Seize Compound on the threads of the bolts (23) and install locks (22) and the bolts (23) to hold the cartridge in position. Tighten the bolts to a torque of 175 ± 15 lb.in. (19.8 ± 1.7 N·m) and bend the tabs of the locks on the bolts.

22. Be sure the O-ring seal is in position on the cartridge assembly. Install compressor housing (24) on the cartridge in the correct position. Install clamps and the bolts that hold housing in position. Tighten the bolts to a torque of 105 ± 5 lb.in. (11.9 ± 0.6 N·m).

end by:

a) install turbocharger