Documentos de Académico
Documentos de Profesional
Documentos de Cultura
Page 1 of 65
Shutdown SIS
Previous Screen
!"#
# $
&
' &
#(
' & )*
&
+(
Turbochargers{1052}
SMCS - 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)
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 2 of 65
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 3 of 65
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 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 and Salvage Guideline, SEBF8019, "Specifications for Reuseable Turbocharger
Components"
ReferenceSpecial Instruction, SMHS6998, "Instructions For The Use Of 5P6518 Fixture Group - Parts
Reusability"
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 4 of 65
Required Tooling
Table 1
Part Number
Description
266-3452
6V-2055
Grease
5P-2170
4M-6646
Grooved Pin
7447
5P-6518
763 N/F
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.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 5 of 65
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.
Illustration 1
g01410053
Masking tape is used on the shaft and the bearing journals for protection from glass beads.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Illustration 2
Cleaned turbine wheel
Page 6 of 65
g01410109
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
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 7 of 65
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
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 8 of 65
Illustration 4
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.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 9 of 65
Illustration 6
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)
Inspection Procedures
Turbine Wheel and Shaft Assembly
Nomenclature
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Illustration 7
(1) Blade
Page 10 of 65
g01410122
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.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 11 of 65
Illustration 8
g01410123
Turbine wheel has cracks in one blade and one broken blade.
Illustration 9
g01410126
The turbine wheel has one slightly bent blade and no cracks.
Illustration 10
g01410131
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 12 of 65
Illustration 11
g01410132
The turbine wheel has a large amount of damage from foreign material.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 13 of 65
Illustration 12
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.
Illustration 13
g01410134
Turbine blades show light damage from rubbing 360 around the turbine wheel.
Illustration 14
g01410135
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 14 of 65
Turbine blades show light damage from rubbing 360 around the turbine wheel.
Illustration 15
Turbine blades show heavy rubbing.
g01410136
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 15 of 65
Illustration 16
g01410138
Turbine wheel shows heavy rubbing on the back face.
Illustration 17
g01410139
The seal ring groove has a wear step in the outboard groove.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 16 of 65
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.
g01410140
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Illustration 19
There is too much wear in both of the seal ring grooves.
Page 17 of 65
g01410142
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.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 18 of 65
Illustration 21
g01410145
Wheel and shaft assembly shows erosion in the hub area of the shaft.
Illustration 22
g01410146
The bearing journal has deep scratches and excessive wear.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 19 of 65
Illustration 23
g01410147
The bearing journal has metal deposits from the bearing.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 20 of 65
Illustration 24
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 .
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.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 21 of 65
Illustration 27
g01410153
The shaft shows discoloration and the shaft can be used again after the shaft is cleaned.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 22 of 65
Illustration 28
g01410155
The shaft was cleaned in order to remove discoloration, carbon deposits and/or deposits of lacquer.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 23 of 65
Illustration 29
g01410156
The shaft shows damage from a compressor wheel that has turned on the shaft.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 24 of 65
Illustration 30
g01410158
The shaft has damage of the threads. The shaft can be made usable by the use of the correct rethreading die.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 25 of 65
Illustration 31
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.
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.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
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.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
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
(1) Blade
g01410163
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.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Illustration 35
Compressor wheel had a broken blade.
Page 28 of 65
g01410164
Illustration 36
g01410165
The compressor wheel has one slightly bent blade. The compressor wheel does not have any cracks.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Illustration 37
Compressor wheel has severely bent blades.
Page 29 of 65
g01410168
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.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 30 of 65
Illustration 39
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.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 31 of 65
Illustration 41
g01410190
Compressor wheel blades show a minor amount of rubbing 360 degrees around the compressor wheel.
Illustration 42
g01410191
Compressor wheel blades show heavy rubbing.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Illustration 43
Compressor wheel has damage on the nut face.
Page 32 of 65
g01410192
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.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
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.)
Compressor Housing
Nomenclature
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Illustration 46
(10) Bore of the outlet
Page 34 of 65
g01410197
Illustration 47
g01410198
The compressor housing shows damage to the vanes from foreign material.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 35 of 65
Illustration 48
g01410200
The compressor housing has light pitting in the bore.
Illustration 49
g01410201
The compressor housing shows damage from foreign material.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 36 of 65
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.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 37 of 65
Illustration 52
g01410204
The compressor housing has deep grooves in the area of the contour of the bore.
Illustration 53
g01410205
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
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
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.
Turbine Housing
Nomenclature
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Illustration 55
(13) Inlet flange
Page 39 of 65
g01410208
Illustration 56
The turbine housing has a crack on the outside.
g01410210
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 40 of 65
Illustration 57
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.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 41 of 65
Illustration 59
g01410214
The turbine housing has minor amounts of erosion on the contour of the bore.
Illustration 60
g01410215
The turbine housing has heavy erosion on the contour of the bore.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 42 of 65
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.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 43 of 65
Illustration 62
g01410217
The turbine housing shows erosion on the web and cracks in the inlet flange. The cracks go into the area of the gasket.
Center Housings
Nomenclature
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Illustration 63
(17) Bore
Page 44 of 65
g01410218
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
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 45 of 65
Illustration 65
g01410220
The center housing has a damaged snap ring groove.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 46 of 65
Illustration 66
g01410221
The center housing has a bore for the seal ring with excessive damage.
Illustration 67
g01410223
The bearing bore in the center housing shows deep scratches and grooves.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 47 of 65
Illustration 68
g01410224
A small number of deep scratches come from the cavity for oil supply.
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.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 48 of 65
Illustration 70
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.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Illustration 71
The center housing shows light erosion.
Page 49 of 65
g01410227
Illustration 72
The center housing shows heavy erosion.
g01410228
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
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.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 51 of 65
7. Use a punch in order to make a mark for the location of the installation of the new pins on the center
housing.
8. 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 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. 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.
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.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 52 of 65
Illustration 75
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.
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 .
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
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.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Illustration 78
The wheel shroud has a crack.
Page 54 of 65
g01410234
Illustration 79
The wheel shroud shows excessive erosion.
g01410235
Illustration 80
g01410236
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 55 of 65
Illustration 81
g01410237
The wheel shroud has discoloration and the wheel shroud can be used again after the wheel shroud is cleaned.
Illustration 82
g01410238
The wheel shroud has discoloration. Half of the shroud has been cleaned with glass beads.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 56 of 65
Illustration 83
g01410239
The flinger sleeve shows no wear and the seal ring groove is within specifications.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 57 of 65
Illustration 84
g01410240
The thrust spacer shows no wear and the seal ring grooves are within specifications.
Illustration 85
The insert shows wear in the area of the bore.
g01410242
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 58 of 65
Illustration 86
g01410243
The insert shows no wear in the area of the bore.
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
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 59 of 65
bore.
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.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 60 of 65
Illustration 90
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
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
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
Thrust bearing shows light wear.
g01410250
Illustration 93
Thrust bearing shows light wear.
g01410251
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 62 of 65
Illustration 94
Thrust bearing shows light wear.
g01410252
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.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 63 of 65
Illustration 96
g01410255
Check the oil hole with a wire. Oil hole must be open and free of foreign material.
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.
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
Page 64 of 65
Illustration 97
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
Rust Preventive
3.79 L (1 US gal)
1U-6523
1U-8801
3.79 L (1 US gal)
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008
1U-6526
!" # $$ % &
( # )( ) * '
*
+ ,.
'
Page 65 of 65
/# 0
% /1 2
% &
) )'
https://10.1.2.37:8443/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 7/10/2008