Media Search - SENR3594 - 3612 and 3616 Engines

6/10/2014 Media Search - SENR3594 - 3612 and 3616 Engines
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Disassembly and Assembly

3612 and 3616 Engines
Media Number -SENR3594-12 Publication Date -01/08/2008 Date Updated -05/08/2008
i05015057
Turbocharger - Assemble
SMCS - 1052-016
Part Number -
S/N - 1PD1-UP
Assembly Procedure For The NA 297 Turbocharger

Table 1
Required Tools
Tool Part Number Part Description Qty
A 178-0193 Torque Wrench Adapter 1
B 178-0196 Torque Wrench Adapter 1
C 177-9781 Lifting Bracket 1

F 177-9791 Shaft Locking Tool 1
H 177-9800 Brace 1
J - Socket 1
K 6V-7820 Torque Multiplier 1
M 1U-8014 Allen Wrench 6mm 1

N 177-9809 Guide Rod 2
P 177-9811 Removal Tool 1

Q 6V-9104 Wrench 30mm 1
R 1U-6683 Ring Expander 1
S 8T-5096 Dial Indicator Group 1

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T - Loctite 648 -
V 5P-3931 Anti-Seize Compound 1

W - Loctite 5900 -
X - Feeler Gauge 1
NOTICE
Check the turbocharger's nameplate for the model. Use the
appropriate assembly procedure depending on the type of
turbocharger. If the model or type on the turbocharger's nameplate
reads C254xx-xxxxxx, use the assembly procedure for the VTC 254
Turbocharger. If the model or type on the turbocharger's nameplate
reads NA 297 or Napier 297, use the assembly procedure for the NA
297 Turbocharger.
Note: The following steps are for the preparation of the bearing housing.
1. Ensure the cleanliness of all the components before reassembly.
2. Ensure that the oil drain plugs are installed in the correct position on the bearing housing.
Illustration 1 g01293400
3. Replace O-ring seal (46) on alternate oil manifold (47) .
4. Secure alternate oil manifold (47) by using the capscrews.
Note: The following steps are for the bearings of the end housings (turbine and compressor).
5. Fit the drain plug to the housing of the turbine end bearing.
6. Install turbine end journal bearing (41) into housing (39) .
7. Apply Tooling (T) to the threads of antirotation screw (42) . Install antirotation screw (42) into
housing (39) .
8. Install retaining ring (40) in order to secure turbine end journal bearing (41) .
9. Install O-ring seal (48) onto the turbine end of housing (39) .
10. Install compressor end journal bearing (45) .
11. Install retaining ring (44) . Retaining ring (44) secures compressor end journal bearing (45) .
12. Apply Tooling (T) onto capscrews (42) . Use capscrews (42) in order to install major thrust
bearing (43) .
13. Install O-ring seal (49) on the compressor end of bearing housing (50) .
Note: The following steps are for the assembly of the bearing housing.
14. Apply Tooling (T) onto the threads of capscrews (38) . Install capscrews (38) which secure
housing (39) of the turbine end bearing.
Note: One hole is offset in order to ensure that the oil feed is at the bottom.
15. Tighten capscrews (38) to a torque of 40 N·m (30 lb ft).
Note: The lockwashers are assembled in pairs. Ensure that the mating teeth fit together.
16. Install cone (37) on bearing housing (35) . Apply Tooling (V) to capscrews (36) . Apply
Tooling (V) onto the threads of capscrews (36) . Secure cone (37) with capscrews (36) and the
lock washers. Tighten capscrews (36) to a torque of 50 N·m (37 lb ft).
17. Install gas outlet housing (24) to the bearing housing.
18. Install safety bolts (34) that connect the bearing housing to gas outlet housing (24) .
Note: The following steps are for the installation of the rotor shaft.
19. Ensure that the rotor is balanced.
20. Install piston ring seals (51) onto the turbine end of rotor shaft (31) . Use Tooling (R) . Ensure
that there are 180 degrees between the gaps.
21. Lubricate piston ring seals (51) and the turbine end bearing with clean engine oil.
22. Install rotor shaft (31) into the bearing housing. Ensure that the turbine end bearing is not
damaged.
23. Install Tooling (F) onto gas outlet housing (24) .
24. Raise the temperature of thrust collar (32) to approximately 100°C (212°F).
25. Apply Tooling (V) onto thrust collar (32) and position the thrust collar onto the shaft.
26. While rotor shaft (31) is pushed completely toward the compressor end, install thrust collar (32)
on rotor shaft (31) . Use Tooling (P) and Tooling (Q) in order to ensure that thrust collar (32) is
fully seated.
27. When the thrust collar has cooled for approximately 15 minutes, remove Tooling (P) .
Note: The following steps are for the installation of the compressor end bearing.
28. Fit the O-ring seals to oil tube (30) .
29. Install oil tube (30) with the O-ring seals into the housing of the turbine end bearing.
30. Liberally oil the thrust bearing and journal bearing with clean engine oil.
31. Install Tooling (N) in the bearing housing in preparation for installing the housing of the
compressor end bearing.
Note: Ensure that oil tube (30) is correctly aligned.
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32. Install housing (29) of the compressor end bearing.
33. Remove Tooling (N) .
34. Apply Tooling (T) to the threads of capscrews (28) . Install capscrews (28) . Tighten the
capscrews to a torque of 40 N·m (30 lb ft).
35. Install Tooling (N) in the bearing housing in preparation for fitting labyrinth seal plate (27) .
36. Install labyrinth seal plate (27) .
37. Apply Tooling (V) on the threads of capscrews (26) . Install capscrews (26) to labyrinth seal
plate (27) .
38. Remove Tooling (N) .
39. Install remaining capscrews (26) . Tighten capscrews (26) to a torque of 40 N·m (30 lb ft).
40. Apply four large spots of Tooling (W) onto the surface of the seal plate.
41. Install diffuser (26) onto bearing housing (22) .
Note: The following steps are for the installation of the impeller.
42. Apply Tooling (V) onto rotor shaft (31) and the threads.
43. Remove piston ring (52) from impeller (20) . Replace piston ring (52) on impeller (20) after the
impeller has been cleaned.
44. Install impeller (20) on rotor shaft (31) . Gently turn impeller (20) by hand until the impeller is
tight.
45. Check the rotor assembly for free rotation. Ensure that there is clearance between the rotor and
the thrust bearing. Push the rotor toward the rear and pull the rotor toward the front.
46. Install diffuser packing ring (25) on the compressor housing. Use Tooling (M) in order to install
the capscrews. The capscrews secure diffuser packing ring (25) .
47. Use a seal on the compressor housing. There are two different ways to seal the compressor
housing to the bearing housing.
a. Compressor housing (11) can be sealed with an O-ring seal (53) .
b. Compressor housing (11) can be sealed by using Tooling (W) .
Note: These two methods are not interchangeable.
48. Fit the compressor housing to the bearing housing. Attach the safety bolts. Fit the spring
washers and nuts.
49. Install Tooling (H) and Tooling (J) in order to tighten the impeller to the correct torque.
50. Install Tooling (K) in order to achieve the proper torque.
51. Tighten the impeller to a torque of 610 N·m (450 lb ft). Use Tooling (H) , Tooling (J) , and
Tooling (K) .
52. Remove Tooling (H) , Tooling (J) , and Tooling (K) .
53. Install Tooling (S) onto gas outlet housing (24) . This dial indicator is a part of Tooling (S) .
Position the tip of the gauge to turbine (19) .
54. Push the rotor toward the turbine end. Hold the rotor in place. Zero the indicator.
55. Push the rotor toward the compressor end. Hold the rotor in place. Record the reading from the
indicator. The clearance must be 0.095 to 0.335 mm (0.004 to 0.013 inch).
Note: This clearance is not adjustable. If the clearance is too small, the rotor has been
assembled incorrectly.
Note: The following steps are for the assembly of the compressor insert.
56. Install Tooling (N) into the compressor housing in the preparation for fitting the compressor
insert.
57. Attach Tooling (C) onto compressor insert (12) .
58. Position the compressor insert onto Tooling (N) .
Note: Use extreme caution when you are pushing the compressor insert into the compressor
housing. Damage to the impeller could occur. The compressor insert must be kept level.
59. Push the compressor insert into the compressor housing.
60. Ensure that the gap between the compressor insert and the compressor housing is equal.
61. Use Tooling (X) in order to measure the gap in four places. Take the average of the
measurements. Record this dimension.
62. Use the following steps in order to calculate the size of the shim:
a. Ensure that the rotor is pushed toward the compressor end. This removes the rotor thrust
clearance.
b. Use the measurement that was recorded in Step 61. Add 0.75 mm (0.0295 inch) to that
measurement. This is the midpoint of the clearance that is required. The number that is
obtained is the size of the shim that is required in order to give the correct impeller
clearance.
Note: The shim's width is variable. Each lamination is 0.05 mm (0.002 inch).
63. Peel off the laminations of the shim until the correct thickness is achieved.
64. Remove the capscrews. Remove the compressor insert with extreme caution.
65. Install O-ring seal (54) onto compressor insert (12) . Moderately lubricate the O-ring seal.
66. Screw the speed sensor into the compressor insert until the end of the speed sensor is flush with
the inner surface of the insert.
Note: Ensure that the speed sensor is flush with the inner surface of the compressor insert.
Failure to ensure this contact could cause impact with the compressor wheel.
67. Fit the shim onto the guide posts.
68. Feed harness assembly (18) for the speed sensor through the hole in the compressor housing.
69. Install compressor insert (12) into compressor housing (11) . Ensure that compressor insert (12)
remains level in order to avoid damage to the impeller. Ensure that the harness assembly for the
speed sensor does not get trapped.
70. Install bolts (13) and install the lock washers. Tighten bolts (13) . Remove Tooling (C) .
71. Tighten gland nut (16) on speed sensor (14) .
72. Use Tooling (X) in order to measure the gap from the tip of an impeller vane to compressor
insert (12) . This measurement should be taken NEXT to speed sensor (14) .
73. Use Tooling (X) in order to measure the gap from the tip of an impeller vane to compressor
insert (12) . This measurement should be taken at the speed sensor. If the reading is different
from Step 72, adjust the speed sensor.
Note: The following steps are for the installation of the housing for the turbine inlet.
74. Place nozzle (10) into the housing for turbine inlet (5) .
75. Place clamping ring (9) onto the nozzle. Align the holes.
76. Apply Tooling (V) to capscrews (8) . Install capscrews (8) and the lock washers to clamping
ring (9) . Tighten the capscrews to a torque of 67.0 N·m (49.42 lb ft).
77. Install seal (7) onto the housing for turbine inlet (5) .
78. Use a suitable lifting device in order to place the housing for turbine inlet (5) on gas outlet
housing (24) . The weight of the housing for turbine inlet (5) is approximately 35 kg (77 lb).
79. Use the spacers and nuts (6) in order to fasten the housing for turbine inlet (5) to gas outlet
housing (24) .
80. Install insulation (4) .
81. Insert cotter pins (3) in latches (2) that hold the insulation in place.
Note: The following steps are for the installation of the turbocharger on the engine.
82. Use a suitable lifting device in order to place the turbocharger into position on the engine.
Note: When you are positioning the turbocharger, ensure that the turbocharger remains level.
Ensure that the O-ring seals for the oil system are not trapped.
83. Install the main bolts in the mounting foot. Tighten the bolts to a torque of 420 N·m (310 lb ft).
Use Tooling (C) .
84. Install the main mounting bolts with Tooling (A) .
85. Connect the connections to the housing for the turbine inlet.
86. Connect the speed sensor connection.

87. Connect the turbocharger wash group, if equipped.
88. Reconnect the instrumentation.
89. Connect the oil system if the oil is supplied externally.
Note: The turbocharger must be filled with oil prior to operation on the engine. After
installation of the turbocharger on the engine, fill the turbocharger with clean engine oil at the
oil supply port. Connect the oil supply line after filling.
Copyright 1993 - 2014 Caterpillar Inc. Mon Oct 06 2014 13:56:08 GMT-0300 (Hora oficial do Brasil)
All Rights Reserved.
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6/10/2014 Media Search - SENR3594 - 3612 and 3616 Engines

Disassembly and Assembly

Assembly Procedure For The NA 297 Turbocharger

Tool Part Number Part Description Qty

A 178-0193 Torque Wrench Adapter 1

B 178-0196 Torque Wrench Adapter 1

C 177-9781 Lifting Bracket 1

M 1U-8014 Allen Wrench 6mm 1

P 177-9811 Removal Tool 1

S 8T-5096 Dial Indicator Group 1

V 5P-3931 Anti-Seize Compound 1

1. Ensure the cleanliness of all the components before reassembly.

3. Replace O-ring seal (46) on alternate oil manifold (47) .

4. Secure alternate oil manifold (47) by using the capscrews.

6. Install turbine end journal bearing (41) into housing (39) .

10. Install compressor end journal bearing (45) .

15. Tighten capscrews (38) to a torque of 40 N·m (30 lb ft).

17. Install gas outlet housing (24) to the bearing housing.

19. Ensure that the rotor is balanced.

23. Install Tooling (F) onto gas outlet housing (24) .

28. Fit the O-ring seals to oil tube (30) .

Note: Ensure that oil tube (30) is correctly aligned.

32. Install housing (29) of the compressor end bearing.

33. Remove Tooling (N) .

36. Install labyrinth seal plate (27) .

38. Remove Tooling (N) .

41. Install diffuser (26) onto bearing housing (22) .

a. Compressor housing (11) can be sealed with an O-ring seal (53) .

b. Compressor housing (11) can be sealed by using Tooling (W) .

Note: These two methods are not interchangeable.

50. Install Tooling (K) in order to achieve the proper torque.

52. Remove Tooling (H) , Tooling (J) , and Tooling (K) .

57. Attach Tooling (C) onto compressor insert (12) .

58. Position the compressor insert onto Tooling (N) .

59. Push the compressor insert into the compressor housing.

67. Fit the shim onto the guide posts.

71. Tighten gland nut (16) on speed sensor (14) .

80. Install insulation (4) .

84. Install the main mounting bolts with Tooling (A) .

86. Connect the speed sensor connection.

87. Connect the turbocharger wash group, if equipped.

88. Reconnect the instrumentation.

89. Connect the oil system if the oil is supplied externally.

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