Disassembly and Assembly of the TPL61 Turbocharger{1052} Caterpillar

Disassembly and Assembly of the TPL61 Turbocharger{1052}

Usage:

3612 9RC

Engine:: 3612 (S/N: 9RC1-UP)

Introduction

This Special Instruction provides the procedures for the disassembly and assembly of the TPL61 Turbocharger. Before you begin any work on the turbocharger, read this instruction in order to understand the entire procedure.

Removal Procedure

Note: Inspect the components for wear or damage. Replace the components, if necessary.

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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NOTICE

Dents in the exhaust bellows can cause failure due to fatigue of the material. Use care to avoid denting of the bellows when you loosen bolts and/or when you handle the bellows.

Disconnect the lines for the exhaust gas, the air, and the oil.

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Illustration 1	g00724968

Loosen clamp (1) in order to remove shield (2) .

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Illustration 2	g00724994

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Illustration 3	g00725001

Remove screws (3) in order to remove shield (4) .

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Personal injury or death can occur from not following the proper procedure or the recommended tooling.

To prevent the possibility of injury or death, follow the established procedure using the recommended tooling.

Note: Take into account the weight of the turbocharger when you select a suitable lifting device. The turbocharger weighs approximately 526 kg (1160 lb). The post on the silencer (if equipped) must not be used to support the weight of the turbocharger when the turbocharger is lifted.

Note: Removal of the components that are related to the turbocharger depends on the specific arrangement. The turbocharger may be equipped with an air silencer or an elbow. Some turbochargers have an axial adapter.

Check the lifting equipment.
Lifting of the turbocharger depends on the design of the turbocharger. Some turbochargers have reinforced eyelets on the bearing casing. Some turbochargers do not have reinforced eyelets on the bearing casing. Use the appropriate method of the following instructions for lifting the turbocharger:
1. For turbochargers with reinforced eyelets on the bearing casing, attach the lifting equipment to the lugs.
1. For turbochargers without reinforced eyelets on the bearing casing, secure the turbocharger at the air inlet and at the casing of the exhaust gas inlet.

Remove the bolts from the foot of the turbocharger.

Lift the turbocharger from the engine. Place the turbocharger on suitable supports. Position the supports underneath the casing.

Cover the connections for the oil to the turbocharger.

Disassembly Procedure

Required Tools

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Table 1
Tools Needed
195-8104 Turbocharger Tool Gp	Description	Quantity
A	Tool Box	1
B	Shackle	1
C	Ring bolt	2
D	Guide tube	1
E	Radial bearing pin	2
F	Press on bushing	1
G	Tommy bar	1
H	Mounting support	2
I	Forcing screw	4
J	Puller screw	3
K	Stud	2
L	Press off tool assembly	2

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Illustration 6	g00697016
195-8104 Turbocharger Tool Gp (A) Tool box (B) Shackle (C) Ring bolt (D) Guide tube (E) Radial bearing pins (F) Press on bushing (G) Tommy bar (H) Mounting supports (I) Forcing screws (J) Puller screws (K) Studs (L) Press off tool assembly

Removal Of The Compressor Casing

Note: Throughout the disassembly, be sure to spin the rotor in order to ensure that the components are properly aligned.

Note: Inspect the components for wear or damage. Replace the components, if necessary.

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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Personal injury or death can occur from not following the proper procedure or the recommended tooling.

To prevent the possibility of injury or death, follow the established procedure using the recommended tooling.

Attach suitable lifting gear to the silencer. The silencer weighs approximately 57 kg (126 lb). Remove the nuts from the air silencer. Lift the silencer from the turbocharger.

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Illustration 7	g00697235

Attach suitable lifting gear to air inlet elbow (1). The air inlet elbow weighs approximately 25 kg (55 lb). Remove nuts (2) from the air inlet elbow. Lift the air inlet elbow away from the turbocharger.

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Illustration 8	g00737798

Remove upper retaining bolt (3) .

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Illustration 9	g00697309

Install Tool (B) into the hole for upper retaining bolt (3) in compressor casing (4). Attach a suitable strap to Tool (B). Also, place the lifting strap underneath wall insert (5). The compressor casing weighs approximately 101 kg (223 lb). Remove the nuts that attach the compressor housing to the bearing housing.

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Illustration 10	g00697336

Use three jacking nuts (6) in order to remove compressor casing (4) .

Remove compressor casing (3). Place the casing on two planks with the wall insert in the downward position.

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Illustration 11	g00697361

Remove retaining bolts (7) from the diffuser.

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Illustration 12	g00697563

Lift out diffuser (8) .

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Illustration 13	g00697375

Attach Tool (C) and a suitable lifting device to wall insert (4). The wall insert weighs approximately 30 kg (66 lb). Lift out the wall insert. Remove 2 O-ring seals (9) .

Removal Of The Cartridge

Note: Inspect the components for wear or damage. Replace the components, if necessary.

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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Illustration 14	g00725253

Remove O-ring seals (1) and (2) .

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Illustration 15	g00697610

Remove speed sensor (3) .
Note: There is no gasket for the sensor. The sensor is a press fitted part.

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Personal injury or death can occur from not following the proper procedure or the recommended tooling.

To prevent the possibility of injury or death, follow the established procedure using the recommended tooling.

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Illustration 16	g00697757

Attach a suitable lifting device to cartridge (4). The cartridge weighs approximately 128 kg (282 lb). Remove the slack from the lifting device in order to support the cartridge. Remove retaining bolts (5).

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Illustration 17	g00697827

Note: Turn the rotor during the disassembly in order to ensure that the shaft does not touch the turbine diffuser.

Install Tool (I) into the cartridge. Evenly press the cartridge from the housing with Tool (I) .

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NOTICE

The blades of the turbine can be damaged during removal and installation of the turbine. To help avoid damage to the blades, keep the cartridge supported. Maintain balance of the cartridge. Be careful not to strike the blades.

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Illustration 18	g00697886

Slowly remove cartridge (4) .

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Illustration 19	g00697937

Attach Tool (H) to the cartridge. Place the cartridge on a hard level surface. Remove forcing screws (I) .

Cover the connections for the oil to the turbocharger.

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Illustration 20	g00698310

Replace the top two bolts in turbine diffuser (6) with Tool (K) .

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Illustration 21	g00698415

Remove the remaining bolts. Install Tool (J). Evenly press off turbine diffuser (6) with Tool (J). Remove the turbine diffuser from the outlet casing.

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NOTICE

The nozzle ring hangs loosely from the positioning pins after the turbine diffuser is removed. Do not allow the nozzle ring to drop.

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Illustration 22	g00698455

Remove nozzle ring (7) .

Disassembly Of The Cartridge

Note: Inspect all components for wear or damage. Replace the components, if necessary.

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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Illustration 23	g00700593

Remove cartridge (2). Attach Tool (H) to the cartridge. Place the cartridge on a hard level surface in order to remove compressor wheel (1) .

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Illustration 24	g00700616

Install hex sockets (3) onto compressor wheel (1) and the end of the shaft on the turbine side.

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Personal injury or death can occur from not following the proper procedure or the recommended tooling.

To prevent the possibility of injury or death, follow the established procedure using the recommended tooling.

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Illustration 25	g00725286

Note: Compressor wheel (1) is fastened to the shaft with a great amount of torque. Be sure that the end of the shaft on the turbine side is adequately blocked before you loosen the nut. Support the weight of the cartridge with a suitable lifting device.

Fit wrenches onto the hex sockets. Use the wrenches to loosen compressor wheel (1) .

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Illustration 26	g00725295

Hold compressor wheel (1). Use a wrench to rotate the turbine end of the shaft in order to remove the compressor wheel.

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Illustration 27	g00725299

Fit Tool (F) and Tool (D) onto the shaft in order to protect the threads.

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Illustration 28	g00725306

Fit Tool (L) onto partition wall (4). Use Tool (L) to press off the partition wall. Remove the partition wall. Remove Tool (D) from the shaft.

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Illustration 29	g00725359

Remove 2 O-ring seals (5) from the partition wall.

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Illustration 30	g00725370

Remove Tool (F) from the shaft. Remove gasket (6) .

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Illustration 31	g00725371

Remove auxiliary bearing (7) .

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Illustration 32	g00725372

Reinstall Tool (F) onto the shaft. Remove three bolts (8) .

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Illustration 33	g00725412

Install three bolts (8) into the other holes. Use the three bolts to evenly press off axial bearing (9) .
After the axial bearing is removed, remove bolts (8) .

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Illustration 34	g00725416

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NOTICE

The floating disc may stick to the axial bearing. Do not allow the floating disc to fall.

Remove axial bearing (9) .

Note: If radial bearing (11) is removed, bolt (10) cannot be reused. A new bolt with the proper coating must be obtained for reassembly of the bearing.

If necessary, remove bolt (10) in order to remove radial bearing (11). Discard the bolt.

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Illustration 35	g00725437

Remove floating disc (12) .

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Illustration 36	g00725535

Loosen Tool (F) from the shoulder of the shaft. Loosen 3 bolts (13) until at least 10 mm (0.4 inch) of the threads are still engaged.

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Illustration 37	g00725543

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NOTICE

In order to prevent any damage to the shaft, press the bearing bushing (15) only as far as necessary for removal of thrust bearing (14) .

Install bolts (8) from Step 16 into the holes of bearing bushing (15). Use the bolts to evenly press thrust bearing (14) and bearing bushing (15) away from the housing.

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Illustration 38	g00725545

Remove Tool (F) from the shaft. Remove thrust bearing (14) .

Tighten bolts (13) hand tight.

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Illustration 39	g00725550

Fit Tool (F) on the shaft. Place the holes in Tool (F) toward the bearing bushing.

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Illustration 40	g00725555

Remove shaft (16) through the rear of the cartridge.

Remove top bolt (13). Install Tool (K) (stud) into the hole for the bolt. Then remove the 2 remaining bolts (13) .

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Illustration 41	g00725560

Remove bearing bushing (15) .

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Illustration 42	g00725562

Note: If radial bearing (17) is removed from the bearing bushing, bolts (18) cannot be reused. New bolts with the proper coating must be obtained for reassembly of the bearing.

If necessary, remove bolts (18) in order to remove radial bearing (17) from the bearing bushing. Discard the bolts.

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Illustration 43	g00725568

Remove three bolts (19) from cover (20) on the rear of the cartridge.

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Illustration 44	g00725569

Install Tool (J) into the bolt holes on cover (20). Use Tool (J) to evenly press off the cover. Remove the cover.

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Illustration 45	g00725573

Remove O-ring seal (21) from the inside of cover (20) .

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Illustration 46	g00725579

Remove hood (21) .

Assembly Procedure

Required Tools

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Table 2
Tools Needed
195-8104 Turbocharger Tool Gp	Description	Quantity
A	Tool Box	1
B	Shackle	1
C	Ring bolt	2
D	Guide tube	1
E	Radial bearing pin	2
F	Press on bushing	1
G	Tommy bar	1
H	Mounting support	2
I	Forcing screw	4
J	Puller screw	3
K	Stud	2
L	Press off tool assembly	2
8T-5096	Dial Indicator Gp	1

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Illustration 47	g00697016
195-8104 Turbocharger Tool Gp (A) Tool box (B) Shackle (C) Ring bolt (D) Guide tube (E) Radial bearing pins (F) Press on bushing (G) Tommy bar (H) Mounting supports (I) Forcing screws (J) Puller screws (K) Studs (L) Press off tool assembly

Assembly Of The Cartridge

Note: Inspect all components for wear or damage. Replace the components, if necessary.

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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Illustration 48	g00725583

Install hood (1) .

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Illustration 49	g00725593

Install O-ring seal (2) onto cover (3) .

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Illustration 50	g00725596

Install cover (3) onto the rear of the cartridge. Make sure that the drain of the cover is in the downward position. Secure the cover with 3 bolts (4). Tighten the bolts to a torque of 65 N·m (48 lb ft).

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Illustration 51	g00725639

Note: Do not reuse the original bolts for the radial bearing. Always use new bolts with the proper coating.

Note: Observe the marks (dot and arrow at top) and observe the division of the holes on the radial bearing. The radial bearing must always remain slightly movable.

If radial bearing (5) was removed from bearing bushing (6), install the bearing. Use Tool (E) to align the bearing. When the bearing is aligned, remove Tool (E) from one of the holes and install a bolt. Then remove Tool (E) from the other hole and install the other bolt. Tighten the bolts to a torque of 30 N·m (22 lb ft).

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Illustration 52	g00725645

Install Tool (K) into the housing of the cartridge. Insert bearing bushing (6) into the housing. Ensure that the mark is at the top.

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Illustration 53	g00725652

Install two of the bolts in order to hold the bearing bushing in the housing. Remove Tool (K). Install the remaining bolt. Tighten the bolts to a torque of 65 N·m (48 lb ft).

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Illustration 54	g00725670

Coat shaft (7) with clean engine oil. Install Tool (F) onto the shaft. Orient the holes of the tool toward the turbine. Insert the shaft through the rear of the cartridge into the bearing bushing.

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Illustration 55	g00725672

Remove Tool (F) from the shaft.

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Illustration 56	g00725677

Coat the inside of thrust bearing (8) with 6V-4876 Lubricant .

Note: To make the installation easier, the thrust bearing can be heated to a maximum temperature of 110 °C (230 °F). Allow the thrust bearing to fully cool before you continue with further operations.

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Illustration 57	g00725681

Push thrust bearing (8) onto the shaft.

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Illustration 58	g00725682

Use a wrench to hold the turbine wheel during installation of the thrust bearing. Use Tool (F) and Tool (G) to push the thrust bearing to a stop.

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Illustration 59	g00725683

Remove Tool (G) from Tool (F). Install floating disc (9) onto the shaft.

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Illustration 60	g00725771

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Illustration 61	g00725774

Install axial bearing (10). Orient the arrow on the bearing to the upward position. Install the bolts. Hand tighten each of the bolts for one half of a turn at a time. Tighten the bolts in this manner until the axial bearing reaches the final position. Tighten the bolts to a torque of 65 N·m (48 lb ft).

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Illustration 62	g00725780

Remove Tool (F) from the shaft. Install auxiliary bearing (11). Orient the notch of the auxiliary bearing inward.

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Illustration 63	g00725783

Note: Always use a new gasket for installation.

Install gasket (12). Orient the cup of the gasket outward.

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Illustration 64	g00725789

Install Tool (F) onto the shaft. Install 2 O-ring seals (13) .

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Illustration 65	g00725804

Use Tool (D) to aid in installation of partition wall (14) .

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Illustration 66	g00725806

Align the mark on partition wall (14) with the mark on the bearing casing at the twelve o'clock position.

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Illustration 67	g00725814

Install O-ring seal (15) around the partition wall.

Remove Tool (D) and Tool (F) from the shaft.

Note: Do not use Molykote or grease to lubricate the shaft.

Lubricate the end of the shaft and the threads of the compressor wheel with clean engine oil.

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Illustration 68	g00725819

Install compressor wheel (16). Hold the compressor wheel on the end of the shaft and use a hex head wrench to rotate the turbine end of the shaft.

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Illustration 69	g00725829

In order to tighten the compressor wheel, the cartridge must be supported by a suitable lifting device. The shaft must be blocked with a hex head wrench in the hexagonal socket of the shaft on the turbine side. Tighten the wheel to a torque of 260 N·m (192 lb ft). Do not overtighten the wheel.

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Illustration 70	g00725844

Use Tool (M) to measure the axial clearance. Place Tool (M) on the nose of the compressor wheel. Be sure to press inward on both ends of the shaft. The minimum axial clearance is 0.34 mm (0.0134 inch). The maximum axial clearance is 0.40 mm (0.0157 inch).

Installation Of The Cartridge

Note: Apply 4C-5598 High Temperature Anti-Seize to all the bolts that are installed in the outlet casing.

Note: Inspect all components for wear or damage. Replace the components, if necessary.

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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Illustration 71	g00698605

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NOTICE

The nozzle ring hangs loosely from the positioning pins. Do not allow the nozzle ring to drop.

Align the nozzle ring (1) with the holes in the outlet casing.

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Illustration 72	g00698671

Install Tool (K) into the upper part of the outlet casing. Press turbine diffuser (2) into position.

Install the bolts into turbine diffuser (2). Remove Tool (K) and install the remaining two bolts. Tighten the bolts to a torque of 65 N·m (48 lb ft).

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Personal injury or death can occur from not following the proper procedure or the recommended tooling.

To prevent the possibility of injury or death, follow the established procedure using the recommended tooling.

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Illustration 73	g00698777

Attach a suitable lifting device to cartridge (3). The cartridge weighs approximately 128 kg (282 lb). Support the weight of the cartridge with the lifting device and remove Tool (H) .

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NOTICE

The blades of the turbine can be damaged during removal and installation of the turbine. To help avoid damage to the blades, keep the cartridge supported. Maintain balance of the cartridge. Be careful not to strike the blades.

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Illustration 74	g00698757

Carefully insert the cartridge (3) into the inlet casing.

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Illustration 75	g00698863

Note: Throughout the assembly process, be sure to rotate the compressor wheel in order to ensure that the components are properly aligned.

Install 2 retaining bolts (4) into the holes. Do not install the uppermost bolt at this time. Tighten the bolts to a torque of 65 N·m (48 lb ft).

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Illustration 76	g00699019

Install O-ring (5) .

Install 3 jacking nuts (6) onto the studs. Separate each nut by 120 degrees.

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Illustration 77	g00698901

Install speed sensor (7). Tighten the sensor to a torque of 60 N·m (44 lb ft).

Installation Of The Compressor Casing

Note: Inspect all components for wear or damage. Replace the components, if necessary.

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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Illustration 78	g00701566

Note: Use the extensions on Tool (C) as a guide for installation of the wall insert.

Install 2 O-rings (2) onto wall insert (1). Attach Tool (C) to the wall insert. Install the wall insert into the compressor casing.

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Illustration 79	g00701581

Install diffuser (3) .

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Illustration 80	g00701589

Install retaining bolts (4). Tighten bolts (4) to the shoulders of the bolts. Then loosen the bolts for 1/4 of a turn (90 degrees). The bolts must be slightly loose. Diffuser (3) must be movable.

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Personal injury or death can occur from not following the proper procedure or the recommended tooling.

To prevent the possibility of injury or death, follow the established procedure using the recommended tooling.

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Illustration 81	g00701605

Install Tool (B) into the top bolt hole of compressor casing (5). Attach suitable lifting gear to Tool (B) and to the wall insert. The compressor casing weighs approximately 101 kg (223 lb). Install the compressor casing.
Install three jacking nuts evenly around the edge of compressor casing (5). Press the compressor casing into the correct position.

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Illustration 82	g00725884

Remove Tool (B). Install remaining nuts (6). Tighten the nuts to a torque of 45 N·m (33 lb ft).

Install the remaining retaining bolt into uppermost hole (7). Tighten the bolt to a torque of 65 N·m (48 lb ft).

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Illustration 83	g00701630

Secure suitable lifting gear to air inlet elbow (8). The air inlet elbow weighs approximately 25 kg (55 lb). Install the air inlet elbow. Install nuts (9). Tighten the nuts to a torque of 35 N·m (26 lb ft).

Install the silencer. The silencer weighs approximately 57 kg (126 lb).

Installation Procedure

Note: Inspect the components for wear or damage. Replace the components, if necessary.

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Uncover the connectors for the oil.

Check the lifting equipment.

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Personal injury or death can occur from not following the proper procedure or the recommended tooling.

To prevent the possibility of injury or death, follow the established procedure using the recommended tooling.

Fix the lifting equipment to the lugs of the bearing casing.
Note: For the bearing casings that are not equipped with reinforced eyelets, secure the turbocharger at the air outlet and the gas inlet casing. Take into account the weight of the turbocharger when you select a suitable lifting device. The turbocharger weighs approximately 526 kg (1160 lb). The post on the silencer must not be used to support the weight of the turbocharger when the turbocharger is lifted.