C280-08 Tier 4 Engine Caterpillar

Turbocharger - Disassemble

Usage:

Disassembly Procedure For The NA 297 Turbocharger

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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
D	177-9852	Guide Rod	1
E	-	Forcing Screws	3
F	177-9791	Shaft Locking Tool	1
G	177-9795	Socket	1
H	177-9800	Brace	1
J	-	Socket	1
K	6V-7820	Torque Multiplier	1
L	439-3940	Link Bracket	2
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

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NOTICE

Check the turbocharger's nameplate for the model. Use the appropriate disassembly procedure depending on the type of turbocharger. If the model or type on the turbocharger's nameplate reads C254xx-xxxxxx, use the disassembly procedure for VTC 254 Turbochargers. If the model or type on the turbocharger's nameplate reads NA 297 or Napier 297, use the disassembly procedure for NA 297 Turbochargers.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat^® products. Dispose of all fluids according to local regulations and mandates.

Disconnect the oil system if the oil is supplied externally.
Disconnect the air pipes and the exhaust bellows.
Disconnect the instrumentation and protect all this instrumentation.
Seal all points until reassembly.
Disconnect the turbocharger wash group, if equipped.
Disconnect the speed sensor connection.
Disconnect the connections to the turbine inlet.
Disconnect the turbine water wash injectors, if equipped.
Attach a suitable lifting device to the lifting points of the turbocharger at the bearing housing and the gas outlet housing.
Use Tooling (A) in order to remove the bolts from the mounting foot of the turbine end.
Remove the main mount bolts.
Note: Use Tooling (C) in order to ensure that the turbocharger remains level during the removal.
Remove the turbocharger from the engine.
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Illustration 1 g03859410
Mount turbocharger (1) on a suitable service platform.
Note: Ensure that turbocharger (1) is mounted securely before more work is performed. Damage may occur if the turbocharger is not mounted properly.
Remove bolts (3). Using two people, remove exhaust adapter (2). The weight of exhaust adapter (2) is approximately 35 kg (77 lb).
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Illustration 2 g03859429
Remove and discard gasket (4).
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Illustration 3 g01290985

Typical Example
Remove nuts (6) and seal (7). Nuts (6) secure the housing for turbine inlet (5).
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Illustration 4 g01290990

Typical Example
Attach a suitable lifting device onto the housing for turbine inlet (5). The weight of the housing for turbine inlet (5) is approximately 35 kg (77 lb).
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Illustration 5 g01290996

Typical Example
Remove the housing for turbine inlet (5) and seal (7).
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Illustration 6 g01291005
Remove capscrews (8) and the lock washers from clamping ring (9) of the nozzle.
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Illustration 7 g01291012
Remove clamping ring (9) of the nozzle.
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Illustration 8 g01291022

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Illustration 9 g00500134
Remove nozzle (10).
Note: The serial number, the part number, and the total area of the blades are marked on nozzle (10). See Illustration 9.
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Illustration 10 g01291034
Attach a suitable lifting device onto compressor housing (11).
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Illustration 11 g01291051
Attach Tooling (C) to compressor insert (12).
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Illustration 12 g01291057
Attach a suitable lifting device to Tooling (C).
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Illustration 13 g01291060
Remove bolts (13) from opposite sides of compressor insert (12).
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Illustration 14 g01291064
Install Tooling (D) in compressor insert (12). Remove remaining bolts (13).
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Illustration 15 g01291072
Remove gland nut (16) for speed sensor (14) and rubber grommet (15).
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Illustration 16 g01291084
If necessary, use Tooling (E) in order to loosen compressor insert (12).
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Illustration 17 g01291210
Remove compressor insert (12) and gasket (17). Ensure that the gasket is not damaged.
Note: Ensure that the cable for the speed sensor passes through the compressor outlet casing as the insert is withdrawn. Damage to the cable could occur.
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Illustration 18 g01291275
When the compressor insert is out of compressor housing (11), withdraw harness assembly (18) for the speed sensor.
Place the speed sensor in a safe place.
Remove Tooling (D).
Note: The torque on the impeller must be broken before the compressor housing is removed. The housing is required in order to mount the Tooling.
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Illustration 19 g01291297
Position Tooling (F) onto turbine (19). Attach Tooling (F) with spacers and nuts.
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Illustration 20 g01291375
Install Tooling (G) onto the nose of impeller (20). Lock Tooling (G) into position with the bolts and with the nuts.
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Illustration 21 g01291380
Install Tooling (H) onto compressor housing (11).
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Illustration 22 g01291398
Install Tooling (J) onto Tooling (H).
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Illustration 23 g01291411
Install Tooling (K) onto Tooling (J).
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Illustration 24 g01291410
Loosen impeller (20) in the counterclockwise direction.
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Illustration 25 g01291424
Remove impeller (20).
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Illustration 26 g01291433
Ensure that safety bolts (23) that connect bearing housing (22) to gas outlet housing (24) are securely in place. Remove through bolts (21).
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Illustration 27 g01291438
Attach Tooling (L) to compressor housing (11). Use a suitable lifting device in order to take the weight of compressor housing (11).
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Illustration 28 g01291445
Remove safety bolts (23) that connect bearing housing (22) to gas outlet housing (24).
Install Tooling (E) evenly until the compressor housing is free.
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Illustration 29 g01291450
Remove compressor housing (11) from bearing housing (22).
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Illustration 30 g01291454

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Illustration 31 g01291455
Use Tooling (M) in order to remove diffuser packing ring (25).
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Illustration 32 g01291460
Remove diffuser (26) from bearing housing (22). Remove the epoxy adhesive from the area behind the diffuser. Use a ScotchBrite cleaner.
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Illustration 33 g01291462

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Illustration 34 g01291465
Remove capscrews (26) from labyrinth seal plate (27).
Install Tooling (N) into labyrinth seal plate (27). Remove remaining capscrews (26) from the labyrinth seal plate.
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Illustration 35 g01291466
Install Tooling (E) in order to loosen labyrinth seal plate (27).
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Illustration 36 g01291468
Remove labyrinth seal plate (27).
Remove Tooling (N).
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Illustration 37 g01291571
Remove capscrews (28) from housing (29) of the compressor end bearing.
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Illustration 38 g01291593
Install Tooling (N). Remove remaining capscrews (28) from housing (29) of the compressor end bearing.
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Illustration 39 g01291606
Use Tooling (E) in order to loosen housing (29) of the compressor end bearing.
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Illustration 40 g01291609
Remove housing (29) of the compressor end bearing.
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Illustration 41 g01291619
Remove Tooling (N) and remove oil tube (30).
Note: Oil tube (30) may still be attached to the housing of the turbine end bearing.
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Illustration 42 g01291654
Install Tooling (F).
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Illustration 43 g01291659
Thread Tooling (P) onto rotor shaft (31) and onto thrust collar (32).
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Illustration 44 g01291673
Use capscrews (33) in order to lock Tooling (P) into position.
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Illustration 45 g01291695
Use Tooling (Q) and Tooling (P) in order to pull thrust collar (32) off rotor shaft (31).
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Illustration 46 g01291711
Remove Tooling (P) and Tooling (Q) with thrust collar (32).
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Illustration 47 g01291722
Remove thrust collar (32) from Tooling (P).
Note: Ensure that thrust collar (32) is stored correctly in order to avoid damage to the face.
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Illustration 48 g01292666

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Illustration 49 g01292718
Remove Tooling (H).
Support the compressor end of rotor shaft (31) before the removal of rotor shaft (31). This will help to prevent damage to the turbine end bearing.
Remove rotor shaft (31) and the turbine from the turbine end.
Note: The rotor shaft should be stored in a safe area.
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Illustration 50 g01292721
Attach Tooling (L) and a suitable lifting device to gas outlet housing (24).
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Illustration 51 g01292736
Remove safety bolts (34) from gas outlet housing (24).
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Illustration 52 g01292969
Use Tooling (E) in order to free gas outlet housing (24) from bearing housing (35).
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Illustration 53 g01292974
Use Tooling (L) and a suitable lifting device in order to remove the gas outlet housing.
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Illustration 54 g01292978
Remove capscrews (36) that secure cone (37) to bearing housing (35).
Note: The cone is heavy. The cone must be supported when you remove the capscrews.
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Illustration 55 g01292981
Remove cone (37).
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Illustration 56 g01292984
Remove capscrews (38) which secure housing (39) of the turbine end bearing.
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Illustration 57 g01292986
Use Tooling (E) in order to remove housing (39).
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Illustration 58 g01292989
Remove retaining ring (40) that secures turbine end journal bearing (41).
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Illustration 59 g01292990
Remove antirotation screw (42) from housing (39).
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Illustration 60 g01292994
Remove turbine end journal bearing (41) from housing (39).
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Illustration 61 g01292998
Remove capscrews (42) that secure major thrust bearing (43).
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Illustration 62 g01293003
Remove major thrust bearing (43).
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Illustration 63 g01293006
Carefully remove retaining ring (44). Retaining ring (44) secures compressor end journal bearing (45).
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Illustration 64 g01293010
Remove compressor end journal bearing (45).