GRPTS Turbochargers

G3516 Engine WPW00001-UP(SEBP4751 - 09) - Document Structure

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Turbochargers{1052} SMCS - 1052 - 1052 Electric Power Generation: SR4 (S/N: 1DJ1-UP) Engine: 1140 (S/N: 36B1-UP) 1673 (S/N: 74B1-UP; 78B1-UP) 1674 (S/N: 94B1-UP) 1676 (S/N: 54B1-UP) 1693 (S/N: 65B1-UP) 3034 (S/N: 7EF1-UP) 3114 (S/N: 5EF1-UP) 3116 (S/N: 7SF1-UP; 2SG1-UP; 2WG1-UP; 4KG1-UP; 4PG1-UP; 1NJ1-UP; 1SK1-UP; 2BK1UP) 3116 T (S/N: 9LN1-UP) 3126 (S/N: 8NM1-UP) 3145 (S/N: 96M1-UP) 3150 (S/N: 97M1-UP) 3160 (S/N: 98M1-UP) 3176 (S/N: 2YG1-UP) 3176B (S/N: 9WK1-UP) 3204 (S/N: 2TB1-UP; 3PC1-UP) 3208 (S/N: 29A1-UP; 30A1-UP; 5YF1-UP; 90N1-UP; 40S1-UP; 75V1-UP; 32Y1-UP; 01Z1-UP; 02Z1-UP; 03Z1-UP; 51Z1-UP) 3304 (S/N: 4XB1-UP; 6YB1-UP; 3TC1-UP; 4PC1-UP; 10E1-UP; 13E1-UP; 83Z1-UP) 3304B (S/N: 1YF1-UP; 9HK1-UP; 8XL1-UP; 1PS1-UP) 3306 (S/N: 4WB1-UP; 7HB1-UP; 2ZC1-UP; 5JC1-UP; 64Z1-UP; 84Z1-UP; 85Z1-UP) 3306B (S/N: 7JB1-UP; 5KD1-UP; 3RG1-UP; 2AJ1-UP; 8JJ1-UP; 9SL1-UP; 2TM1-UP; 9NR1UP; 1RS1-UP; 63Z1-UP) 3406 (S/N: 92U1-UP) 3406B (S/N: 7FB1-UP; 8TC1-UP) 3408B (S/N: 9TD1-UP; 1LG1-UP; 2BG1-UP) 3408C (S/N: 1TS1-UP) 3408E (S/N: 7PR1-UP) 3412 (S/N: 9XF1-UP; 2WJ1-UP; BCS1-UP) 3412C (S/N: BAK1-UP; 9BR1-UP)


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3412E (S/N: 4CR1-UP) 3508 (S/N: 6TJ1-UP; 5XM1-UP; 3LS1-UP; 3PS1-UP; 95Y1-UP; 96Y1-UP; 97Y1-UP; 23Z1-UP; 68Z1-UP; 69Z1-UP; 70Z1-UP) 3508B (S/N: S2D1-UP; 1TW1-UP; 2HW1-UP; 3DW1-UP; BPX1-UP) 3512 (S/N: 2WK1-UP; 6PM1-UP; 3MS1-UP; 3RS1-UP; 3WS1-UP; 49Y1-UP; 50Y1-UP; 51Y1UP; 24Z1-UP; 65Z1-UP; 66Z1-UP; 67Z1-UP) 3512B (S/N: BRC1-UP; 8EM1-UP; 1PW1-UP; 2GW1-UP; 3ZW1-UP) 3512C (S/N: LLB1-UP; LLF1-UP) 3516 (S/N: 4XF1-UP; 9KF1-UP; 4MJ1-UP; 5SJ1-UP; 7KM1-UP; 3NS1-UP; 3XS1-UP; 27Z1-UP; 28Z1-UP; 29Z1-UP; 71Z1-UP; 72Z1-UP; 73Z1-UP) 3516B (S/N: CBN1-UP; 6HN1-UP; 7RN1-UP; 8CN1-UP; 8KN1-UP; 9AN1-UP; S2P1-UP; S2R1UP; 1NW1-UP; 2FW1-UP; 2JW1-UP; 3CW1-UP; 4BW1-UP; S2Z1-UP) A330A (S/N: 85B1-UP) D330 (S/N: 82B1-UP; 99B1-UP) D330A (S/N: 86B1-UP) D333 (S/N: 80B1-UP; 87B1-UP) D333A (S/N: 88B1-UP) D333C (S/N: 09A1-UP) D334 (S/N: 92B1-UP; 93B1-UP) D336 (S/N: 55B1-UP; 60B1-UP) D342C (S/N: 50B1-UP) D343 (S/N: 33B1-UP; 62B1-UP) D346 (S/N: 39J1-UP; 40J1-UP; 98N1-UP) D348 (S/N: 36J1-UP; 38J1-UP; 57K1-UP) D349 (S/N: 61P1-UP; 62P1-UP; 32R1-UP) D353E (S/N: 77B1-UP) D379 (S/N: 76B1-UP) D379B (S/N: 34Z1-UP) D398 (S/N: 75B1-UP) D398B (S/N: 35Z1-UP) D399 (S/N: 35B1-UP; 91B1-UP; 36Z1-UP) G3304 (S/N: 37Y1-UP) G3306 (S/N: 3CF1-UP; 07Y1-UP) G3406 (S/N: 4FD1-UP; 1RK1-UP) G3408 (S/N: 6NB1-UP; 6RJ1-UP) G3408C (S/N: 3WR1-UP; 8YR1-UP; 6FW1-UP) G3412 (S/N: 7DB1-UP; 3NK1-UP) G3412C (S/N: 6ZM1-UP; 8LW1-UP) G342 (S/N: 71B1-UP) G343 (S/N: 97N1-UP) G348 (S/N: 92R1-UP) G349 (S/N: 93R1-UP) G3508 (S/N: 2JF1-UP; 9TG1-UP; 2TJ1-UP; WPM1-UP; WPN1-UP; DLR1-UP) G3512 (S/N: 4KC1-UP; 5JD1-UP; 7NJ1-UP; WPP1-UP; WPR1-UP; GNS1-UP; 6JW1-UP) G3516 (S/N: 3RC1-UP; 8LD1-UP; 4EK1-UP; 5PN1-UP; WPS1-UP; WPT1-UP; WPW1-UP; 8PW1-UP) G3524 (S/N: 7SZ1-UP) G3532 (S/N: 8BZ1-UP) G399 (S/N: 49C1-UP) : 3306 (S/N: 76R1-UP; 02B1-UP; 04B1-UP; 05B1-UP; 23C1-UP; 66D1-UP; 67D1-UP; 68D1-UP; 70R1-UP; 4TB1-UP; 3ZJ1-UP; 5KJ1-UP; 4CK1-UP; 4JK1-UP; 2WB1-UP; 4RG1-UP; 67U1-UP; 99U1-UP; 28V1-UP; 78Z1-UP; 8RG1-UP; 60M1-UP; 38S1-UP; 81Z1-UP; 25Z1-UP; 31B1-UP;


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3412E (S/N: 4CR1-UP) 3508 (S/N: 6TJ1-UP; 5XM1-UP; 3LS1-UP; 3PS1-UP; 95Y1-UP; 96Y1-UP; 97Y1-UP; 23Z1-UP; 68Z1-UP; 69Z1-UP; 70Z1-UP) 3508B (S/N: S2D1-UP; 1TW1-UP; 2HW1-UP; 3DW1-UP; BPX1-UP) 3512 (S/N: 2WK1-UP; 6PM1-UP; 3MS1-UP; 3RS1-UP; 3WS1-UP; 49Y1-UP; 50Y1-UP; 51Y1UP; 24Z1-UP; 65Z1-UP; 66Z1-UP; 67Z1-UP) 3512B (S/N: BRC1-UP; 8EM1-UP; 1PW1-UP; 2GW1-UP; 3ZW1-UP) 3512C (S/N: LLB1-UP; LLF1-UP) 3516 (S/N: 4XF1-UP; 9KF1-UP; 4MJ1-UP; 5SJ1-UP; 7KM1-UP; 3NS1-UP; 3XS1-UP; 27Z1-UP; 28Z1-UP; 29Z1-UP; 71Z1-UP; 72Z1-UP; 73Z1-UP) 3516B (S/N: CBN1-UP; 6HN1-UP; 7RN1-UP; 8CN1-UP; 8KN1-UP; 9AN1-UP; S2P1-UP; S2R1UP; 1NW1-UP; 2FW1-UP; 2JW1-UP; 3CW1-UP; 4BW1-UP; S2Z1-UP) A330A (S/N: 85B1-UP) D330 (S/N: 82B1-UP; 99B1-UP) D330A (S/N: 86B1-UP) D333 (S/N: 80B1-UP; 87B1-UP) D333A (S/N: 88B1-UP) D333C (S/N: 09A1-UP) D334 (S/N: 92B1-UP; 93B1-UP) D336 (S/N: 55B1-UP; 60B1-UP) D342C (S/N: 50B1-UP) D343 (S/N: 33B1-UP; 62B1-UP) D346 (S/N: 39J1-UP; 40J1-UP; 98N1-UP) D348 (S/N: 36J1-UP; 38J1-UP; 57K1-UP) D349 (S/N: 61P1-UP; 62P1-UP; 32R1-UP) D353E (S/N: 77B1-UP) D379 (S/N: 76B1-UP) D379B (S/N: 34Z1-UP) D398 (S/N: 75B1-UP) D398B (S/N: 35Z1-UP) D399 (S/N: 35B1-UP; 91B1-UP; 36Z1-UP) G3304 (S/N: 37Y1-UP) G3306 (S/N: 3CF1-UP; 07Y1-UP) G3406 (S/N: 4FD1-UP; 1RK1-UP) G3408 (S/N: 6NB1-UP; 6RJ1-UP) G3408C (S/N: 3WR1-UP; 8YR1-UP; 6FW1-UP) G3412 (S/N: 7DB1-UP; 3NK1-UP) G3412C (S/N: 6ZM1-UP; 8LW1-UP) G342 (S/N: 71B1-UP) G343 (S/N: 97N1-UP) G348 (S/N: 92R1-UP) G349 (S/N: 93R1-UP) G3508 (S/N: 2JF1-UP; 9TG1-UP; 2TJ1-UP; WPM1-UP; WPN1-UP; DLR1-UP) G3512 (S/N: 4KC1-UP; 5JD1-UP; 7NJ1-UP; WPP1-UP; WPR1-UP; GNS1-UP; 6JW1-UP) G3516 (S/N: 3RC1-UP; 8LD1-UP; 4EK1-UP; 5PN1-UP; WPS1-UP; WPT1-UP; WPW1-UP; 8PW1-UP) G3524 (S/N: 7SZ1-UP) G3532 (S/N: 8BZ1-UP) G399 (S/N: 49C1-UP) : 3306 (S/N: 76R1-UP; 02B1-UP; 04B1-UP; 05B1-UP; 23C1-UP; 66D1-UP; 67D1-UP; 68D1-UP; 70R1-UP; 4TB1-UP; 3ZJ1-UP; 5KJ1-UP; 4CK1-UP; 4JK1-UP; 2WB1-UP; 4RG1-UP; 67U1-UP; 99U1-UP; 28V1-UP; 78Z1-UP; 8RG1-UP; 60M1-UP; 38S1-UP; 81Z1-UP; 25Z1-UP; 31B1-UP;


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32B1-UP; 46B1-UP; 47B1-UP; 69B1-UP; 66B1-UP; 67B1-UP) Generator Set: 3406 GEN SET (S/N: 4ZR1-UP; 75Z1-UP) 3406B GEN SET (S/N: 4PM1-UP) 3406C GEN SET (S/N: 1LS1-UP; 8FS1-UP) 3412C GEN SET (S/N: BAX1-UP) Industrial Engine: 3054C (S/N: 3341-UP) 3406 IND (S/N: 90U1-UP) 3406B IND (S/N: 6TB1-UP) 3412E IND (S/N: BDT1-UP) D342C IND (S/N: 05A1-UP; 49B1-UP) Marine Engine: 3406 MARINE (S/N: 91U1-UP) 3406C MARINE (S/N: 1SS1-UP) 3408C MARINE (S/N: 9ER1-UP) 3412E MARINE (S/N: 9PW1-UP) Track-Type Tractor: 4S (S/N: 02A1-UP)

Introduction This Reuse and Salvage Guideline contains the necessary information in order 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 in order 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 infor mation that is available from Caterpillar. For additional information about this guideline, consult Repair Process Engineering of the Marketing & Product Support Division at 1 (309) 675-5434.

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 in order 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: Use 6V-2055 Grease in the seal ring grooves during all turbocharger reconditioning.

References ReferenceReuse ReferenceReuse and Salvage Guideline, SEBF8019, "Specifications for Reuseable Turbocharger Components" ReferenceSpecial ReferenceSpecial Instruction, SMHS6998, "Instructions For The Use Of 5P6518 Fixture Group - Parts Reusability"


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ReferenceCatalog, NENG2500, "Dealer Service Tools Catalog"

Service Level of the Turbocharger The service level of the turbocharger determines the components of the turbocharger that should be disassembled. The service level of the turbocharger determines the reusability of the individual parts. The service level of a turbocharger determines the components that should be disassembled. If the assembly of 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 nonserviceable.

Required Tooling Table 1 Part Number

Description

266-3452

Emery Polishing Paper

6V-2055

Grease

5P-2170

Dial Bore Gauge Group

4M-6646

Grooved Pin

7447

3M Type A Scotch-Brite Very Fine General Purpose Pad.

5P-6518

Dial Indicator Fixture Gp

763 N/F

Magnus Heavy-Duty Carbon Solvent

Specifications Some parts will need to be measured in order to know if the parts can be used again. The methods of measurement will be given in respective sections in this guideline. Note: Refer to Reuse and Salvage Guideline, SEBF8019, "Specifications for Reuseable Turbocharger Components" for specifications of wear.

Cleaning Procedures General Improper care of parts during disassembly and assembly can cause a future failure of the turbocharger. Inspect the parts for defects in order 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.


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NOTICE Do not use caustic solutions, wire brushes, or wire wheels to remove carbon deposits from any turbocharger part.

Removal of carbon deposits on some parts is difficult with solvent. Those parts can be cleaned with glass beads. Use glass beads (size 10) that are 0.08 mm (0.003 inch) to 0.15 mm (0.006 inch) with 551.6 kPa (80.00 psi) to 620.5 kPa (90.00 psi) air pressure. 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 in order to prevent corrosion.

Turbine Wheels and Shaft Assemblies

Illustration 1

g01410053

Masking tape is used on the shaft and the bearing journals for protection from glass beads.


Illustration 2

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g01410109

Cleaned turbine wheel

Note: Do not allow the glass beads to hit the bearing journals. 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 . Lacquer and carbon deposits that can not be removed from the shaft with a heavy-duty carbon solvent and bristle brush can be removed with a Scotch-Brite very 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 in order to prevent rust and corrosion.

Compressor Wheels


Illustration 3

g01410114

Compressor wheel that was cleaned with glass beads

NOTICE 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.

Center Housing

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Illustration 4

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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.

Illustration 5

g01410120

Remove carbon deposits from the draining cavity with a carbon scraper. The carbon scraper can be made from 1.5 mm (0.06 inch) thick mild steel.

NOTICE Never assemble a turbocharger before the center housing is thoroughly cleaned with a heavy duty carbon solvent.


Illustration 6

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g01410121

Dimensions for making a carbon scraper from 1.5 mm (0.06 inch) thick mild steel (A) 9.7 mm (0.38 inch) (B) 19.1 mm (0.75 inch) (C) 38.1 mm (1.50 inch) (D) 3.8 mm (0.15 inch) (E) 228.6 mm (9.00 inch) (F) 2.29 mm (0.090 inch) (G) 38.1 mm (1.50 inch)

Compressor and Turbine Housings After cleaning, use air under pressure to remove foreign material from the inside of the housings.

Inspection Procedures Turbine Wheel and Shaft Assembly Nomenclature


Illustration 7

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g01410122

(1) Blade (2) Oil ring groove (3) Threaded area (4) Bearing journals (5) Hub area

Blades 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. Use the Zyglofluorescent penetrant process in order to inspect the assembly of the turbine wheel and shaft for cracks. For information on Zyglo, contact the following company. Magnaflux Corporation 3624 W. Lake Ave. Glenview, Il 60026 http://www.magnaflux.com/country.htm Telephone: 800-421-1569

Note: Do not straighten bent blades.


Illustration 8

g01410123

Turbine wheel has cracks in one blade and one broken blade.

Do not use the part again.

Illustration 9

g01410126

The turbine wheel has one slightly bent blade and no cracks.

Use the part again.

Illustration 10

g01410131

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Turbine wheel has severely bent blades.


Illustration 11

g01410132

The turbine wheel has a large amount of damage from foreign material.


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Illustration 12

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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 13

g01410134

Turbine blades show light damage from rubbing 360° around the turbine wheel.

Use the part again.

Illustration 14

g01410135


Turbine blades show light damage from rubbing 360° around the turbine wheel.

Use the part again.

Illustration 15 Turbine blades show heavy rubbing.

Do not use the part again. Back Face of Turbine Wheel

g01410136

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Illustration 16

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g01410138

Turbine wheel shows heavy rubbing on the back face.

Do not use the part again. Oil Seal Ring Grooves 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. 1. Use a micrometer to measure the width of a new oil seal ring. Record this dimension. 2. 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. 3. 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 in the Reuse and Salvage Guideline, SEBF8019, "Specifications for Reusable Turbocharger Components", then the turbine wheel and shaft assembly cannot be used again.

Illustration 17

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


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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: At all times, use 6V-2055 Grease in the seal ring grooves before the seal rings are installed. This grease helps the seal rings in order to prevent leakage when the turbocharger is first put into operation.

Illustration 18 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.

g01410140


Illustration 19

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g01410142

There is too much wear in both of the seal ring grooves. (6) Outboard groove (7) Turbine wheel


Illustration 20

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 in order to be used again.



Illustration 21

g01410145

Wheel and shaft assembly shows erosion in the hub area of the shaft.

Use the part again. Bearing Journals

Illustration 22

g01410146

The bearing journal has deep scratches and excessive wear.


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Illustration 23

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g01410147

The bearing journal has metal deposits from the bearing.

Do not use the part again. 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 . 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 in the Reuse and Salvage Guideline, SEBF8019, "Specifications for Reusable Turbocharger Components", then the turbine wheel and the shaft assembly can not 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 24

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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 266-3452 Emery Polishing Paper .

Use the partagain after polishing.

Illustration 25

g01410151

The bearing journal in Illustration 24 after the bearing journal was polished.

Illustration 26

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.


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Use the part again after polishing. Shaft Areas 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 27

g01410153

The shaft shows discoloration and the shaft can be used again after the shaft is cleaned.

Use the partagain 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 and checked to Reuse and Salvage Guideline, SEBF8019, "Specifications for Reuseable Turbocharger Components". Finally, the bearing journals must be cleaned in a good solvent.


Illustration 28

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g01410155

The shaft was cleaned in order to remove discoloration, carbon deposits and/or deposits of lacquer.

Use the part again.


Illustration 29

g01410156

The shaft shows damage from a compressor wheel that has turned on the shaft.


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Illustration 30

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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.

Bend of the Shaft


Illustration 31

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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 0.05 mm (0.002 inch). The scale is used for illustration purposes only. Do not use a scale or a straight edge to check for a bent shaft.

Use the part again after the shaft is straightened.

Illustration 32

g01410160

Use 5P-6518 Dial Indicator Fixture Gp to check for bent shafts.

Process of Measuring Use the 5P-6518 Dial Indicator Fixture Gp and the following procedure to measure the bend in wheel and shaft assemblies.


Page 26 of 65

1. Put the wheel and shaft assembly in 5P-6518 Dial Indicator Fixture Gp 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 . 2. Put the dial indicator next to the threaded area on the shaft. Adjust the dial indicator to zero. 3. 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. 4. While the wheel and shaft assembly is turned, look at the dial indicator in order 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. Procedure to Straighten If the TIR is more than 0.05 mm (0.002 inch) put a mark with a pencil on the shaft at the highest indicator reading and use the procedure that follows to straighten the shaft. 1. Remove the wheel and shaft assembly from the 5P-6518 Dial Indicator Fixture Gp . Make sure that the mark on the shaft is visible.

NOTICE Do not put the threaded end of the shaft on a metal table or other hard surfaces when the shaft is hit. These surfaces will damage the threads on the shaft.

Illustration 33

g01410161

Hit the shaft lightly with a plastic or a lead hammer. The shaft must be on a piece of wood.

2. Put the wheel and shaft assembly on a piece of softwood. Turn the shaft until the mark is up. Lightly hit the shaft in the lower area of the bearing journal with a plastic or a lead hammer.


Page 27 of 65

3. Put the wheel and shaft assembly in the 5P-6518 Dial Indicator Fixture Gp and check the TIR again. If the TIR is more than 0.05 mm (0.002 inch) the shaft must be straightened until the TIR is correct.

Compressor Wheel Nomenclature

Illustration 34

g01410163

(1) Blade (8) Nut Face (9) Bore

Blades Compressor wheels that have cracked blades, severely bent blades, or broken blades can not 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 35

Page 28 of 65

g01410164

Compressor wheel had a broken blade.

Do not use the part again. Note: Do not straighten bent blades.

Illustration 36

g01410165

The compressor wheel has one slightly bent blade. The compressor wheel does not have any cracks.

Use the part again.


Illustration 37

Page 29 of 65

g01410168

Compressor wheel has severely bent blades.


Illustration 38

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 266-3452 Emery Polishing Paper to remove the burrs.

Use the part again.


Illustration 39

Page 30 of 65

g01410187

Compressor wheel shows a large amount of damage from foreign material.


Illustration 40

g01410189

Compressor wheel blades show a minor amount of rubbing 360 degrees around the compressor wheel.

Use the part again.


Illustration 41

Page 31 of 65

g01410190

Compressor wheel blades show a minor amount of rubbing 360 degrees around the compressor wheel.

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 42

g01410191

Compressor wheel blades show heavy rubbing.

Do not use the part again. Nut Face 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 43

g01410192

Compressor wheel has damage on the nut face.

Back Face Compressor wheels that have rubbing on back faces cannot be used again.

Illustration 44

g01410194

Compressor wheel shows rubbing on the back face.


Page 32 of 65


Page 33 of 65

Bore

Illustration 45

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.

Compressor Housing Nomenclature


Illustration 46

g01410197

(10) Bore of the outlet (11) Bore of the inlet and contour (12) Vanes

Contour Bore and Vanes

Illustration 47

g01410198

The compressor housing shows damage to the vanes from foreign material.


Page 34 of 65


Illustration 48

Page 35 of 65

g01410200

The compressor housing has light pitting in the bore.

Use the part again.

Illustration 49

g01410201

The compressor housing shows damage from foreign material.

Do not use the part 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 50

g01410202

Compressor housings show light rubbing in the area of the contour of the bore.

Illustration 51

g01410203

Compressor housings show light rubbing in the area of the contour of the bore.

Use the part again.

Page 36 of 65


Illustration 52

Page 37 of 65

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 53 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 0.05 mm (0.002 inch). (J) 230.2 mm (9.0630 inch) diameter

g01410205


Page 38 of 65

(K) 75.66 ± 0.05 mm (2.979 ± 0.002 inch) concentric within ± 0.05 mm (± 0.002 inch) TIR with 230.2 mm (9.0630 inch) diameter (L) This area must be reworked by hand in order 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 in order to remove the sharp change in shape from the straight bore. The area should have a minimal change in shape.

Illustration 54

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. Bores for the O-Rings 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.

Turbine Housing Nomenclature


Illustration 55

g01410208

(13) Inlet flange (14) Contour of the bore

Illustration 56 The turbine housing has a crack on the outside.


g01410210

Page 39 of 65


Illustration 57

Page 40 of 65

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 can not be used again. (15) Cracks that extend past the seal flange (16) Crack

Bolt Holes

Illustration 58

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. Contour of the Bore

Illustration 59

g01410214

The turbine housing has minor amounts of erosion on the contour of the bore.

Use the part again.

Illustration 60

g01410215

The turbine housing has heavy erosion on the contour of the bore.

Page 41 of 65


Page 42 of 65

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 61

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 with a grinding wheel.

Use the part again. Note: Remove the deposit of material only. Do not change the shape of the contour of the bore. Inlet Flange 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 in order to measure the width and the length of the inlet flange. If the amount of warp is more than 0.25 mm (0.010 inch), then the inlet flange can be machined in order to get the flange within specifications. A maximum of 0.25 mm (0.010 inch) material can be machined from the inlet flange. Note: A gasket with a dividing web must be used if the turbine housing has a dividing web and the exhaust manifold has a dividing web. If either of the two does not have a dividing web, use a gasket without a dividing web.


Illustration 62

Page 43 of 65

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. Bore for Outlet 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.

Center Housings Nomenclature


Illustration 63

g01410218

(17) Bore (18) Oil hole

Illustration 64

g01410219

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

Snap Ring Grooves

Page 44 of 65


Illustration 65

Page 45 of 65

g01410220

The center housing has a damaged snap ring groove.

Do not use the part again. Bore for the Oil Seal Ring 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 amount 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 Group and the correct master ring. Center housings with a bore for the seal ring that is larger than the dimension in the Reuse and Salvage Guideline, SEBF8019, "Specifications for Reusable Turbocharger Components" can not be used again.


Illustration 66

Page 46 of 65

g01410221

The center housing has a bore for the seal ring with excessive damage.

Do not use the part again. Bearing Bore Center housings can not 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 67

g01410223

The bearing bore in the center housing shows deep scratches and grooves.


Page 47 of 65


Illustration 68

g01410224

A small number of deep scratches come from the cavity for oil supply.

Use the part again.

Illustration 69

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 70

Page 48 of 65

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 Group . 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 in the Reuse and Salvage Guideline, SEBF8019, "Specifications for Reusable Turbocharger Components" can not 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. Area of the Flange 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 in order 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 1.57 mm (0.062 inch) inside the outside diameter of the flange. The measurement must be 4.11 mm (0.162 inch) to 4.24 mm (0.167 inch) in order to use the housing again.


Illustration 71

g01410227

The center housing shows light erosion.

Use the part again.

Illustration 72

g01410228

The center housing shows heavy erosion.


Retaining Pins for the Thrust Washer

Page 49 of 65


Page 50 of 65

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 73

g01410229

The center housing has damaged retaining pins of the thrust washer.

Do not use the part again. Installation of New Retaining Pins 1. Remove the the damaged damaged pins or the broken broken pins with a sharp sharp chisel chisel and a hammer. hammer. Be careful careful not to damage the contact surface of the thrust washer. If the surface is damaged, the thrust bearing will not lie flat. 2. Grind any remaini remaining ng part of the pins pins so the pins are are even with with the surface surface of the center center housing. housing. There must not be any of the pin above the surface of the center housing. 3. Put the turbine turbine wheel wheel and shaft shaft assembly assembly in position position on the correct correct service service tool of the turbine turbine holder. Install the turbine and end bearing on the shaft assembly. If necessary, refer to the Catalog, NENG2500, "Dealer Service Tools Catalog" for the correct turbine holder. 4. Install Install the center center housing housing with with the damaged damaged pins pins on the shaft shaft assembly. assembly. 5. Install Install the the compressor compressor end bearing bearing on on the shaft assembly. assembly. 6. Put a new thrust thrust washer washer in position position on the center center housing housing so the holes holes in the washer washer are in alignmen alignmentt 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 in order to keep the thrust washer in the center position. Be sure to remove the grease with solvent before the turbocharger is assembled.


Page 51 of 65

7. Use a punch punch in order to make make a mark for the locati location on of the installa installation tion of the new new pins on the center center housing. 8. Drill the the two holes holes for the new pins. pins. The two holes holes should have have a 2.405 ± 0.023 mm mm (0.0947 ± 0.0009 0.0009 inch) diameter. The depth of the two holes should be 5.00 ± 0.20 mm (0.1969 ± 0.0079 inch). Drill a 3.40 ± 0.51 mm (0.1339 ± 0.0201 inch) diameter by a 45 degrees counterbore. 9. Insta nstall ll new 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.

Miscellaneous Parts Thrust Collar or Ring

Illustration 74

g01410230

The thrust collar has deep scratches and grooves. Do not machine the thrust collar in order to remove wear.



Illustration 75

Page 52 of 65

g01410231

The thrust collar has light scratches and the thrust collar can be used again after the thrust collar is cleaned with 266-3452 Emery Polishing Paper . Put the paper on glass or a surface plate and add oil. Then, turn the thrust collar on the paper. Wash the thrust collar in a clean solvent and put the oil on the thrust collar in order to prevent rust.

Use the part again.

Illustration 76

g01410232

The thrust collar has shiny areas and the thrust collar can be used again after the thrust collar is cleaned with 266-3452 Emery Polishing Paper .

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.


Page 53 of 65

Note: Thrust collars that are turned over can not be used again. The end play of the assembly of the turbine wheel and shaft must be checked after a thrust collar or a thrust ring is installed. Check the correct Service Manual for the end play of the shaft assembly.

Illustration 77

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. Wheel Shroud


Illustration 78

g01410234

The wheel shroud has a crack.


Illustration 79

g01410235

The wheel shroud shows excessive erosion.


Illustration 80

g01410236

Page 54 of 65


Page 55 of 65

The wheel shroud shows damage from contact of the shaft.


Illustration 81

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 82

g01410238

The wheel shroud has discoloration. Half of the shroud has been cleaned with glass beads.


Page 56 of 65

Use the part again. Finger Sleeves and Thrust Spacers 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 can not be used again. Use the procedure that follows to measure the width of the seal ring grooves. 1. Make sure that the seal ring grooves are clean and free of carbon. 2. 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. 3. 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. 4. 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 can not be used again.

Illustration 83

g01410239

The flinger sleeve shows no wear and the seal ring groove is within specifications.

Use the part again.


Illustration 84

g01410240

The thrust spacer shows no wear and the seal ring grooves are within specifications.

Use the part again. Insert For The Compressor End Some turbochargers have an insert at the compressor end of the shaft assembly.

Illustration 85 The insert shows wear in the area of the bore.

g01410242

Page 57 of 65


Page 58 of 65


Illustration 86

g01410243

The insert shows no wear in the area of the bore.

Use the part again. Thrust Plates

Illustration 87

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 88

g01410247

The thrust plate shows deep scratches and grooves in the washer.


Illustration 89

g01410245

The thrust plate shows excessive wear in the bore. The thrust plate also shows cracks in the bore.


Page 59 of 65


Illustration 90

Page 60 of 65

g01410248

The washer on the thrust plates has turned. The washer is over part of the pins that hold the washer.


Illustration 91

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 can not 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 in order to prevent rust. Thrust Bearings


Page 61 of 65

The thrust bearings have a lead tin overlay and this overlay will be removed during the operation of the turbocharger. If the thrust bearings have light wear or small amounts of lead tin overlay that has been removed then the bearing can be used again. Thrust bearings that show deep scratches, grooves or excessive wear on either face can not be used again.

Illustration 92

g01410250

Thrust bearing shows light wear.

Illustration 93 Thrust bearing shows light wear.

g01410251


Page 62 of 65

Use the part again.

Illustration 94

g01410252

Thrust bearing shows light wear.

Use the part again.

Illustration 95

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.


Illustration 96

Page 63 of 65

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.

Storage Procedures Proper protection of the part from corrosion is very important. Corrosion will start in as little as one hour after the part has been cleaned. When the part will not be inspected for one hour or less the part should be coated with a rust or corrosion inhibitor or coated with clean engine oil. The part should be individually wrapped in order to prevent contamination, and the part should be stored in a protected area in order to avoid damage. See Illustration 97. When the part will not be inspected in two days or more, the part should be coated with a rust or corrosion inhibitor or coated with clean engine oil and the part should be individually wrapped. The wrapped part should be placed in a container which is clean and structurally solid. The container should be covered or wrapped in plastic in order to prevent damage and contamination to the part. See Illustration 98. See Table 2 for recommended rust inhibitors.


Illustration 97

Page 64 of 65

g01245635

Example of protection for a component that is stored for a shorter term

Illustration 98

g01245640

Example of protection for a component that is stored for a longer term

Table 2 Recommendations for Storage Part Number

Quantity

Description

Storage Protection Hard film

222-3121

1U-8809

355 mL (12 oz) Aerosol

Rust Preventive

Up to one year storage Outside conditions for storage

3.79 L (1 US gal)

One year storage Caterpillar 450Rust Preventive Oil

1U-6523

Covered conditions for storage

208 L (55 US gal)

Wax film 1U-8801

3.79 L (1 US gal)

Caterpillar 4ARust Preventive Oil

Up to one year storage

GRPTS Turbochargers

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