C280-08 Tier 4 Engine Caterpillar

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.
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   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.
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   Illustration 2	g01292994

6. Install turbine end journal bearing (41) into housing (39).
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   Illustration 3	g01292990

7. Apply Tooling (T) to the threads of antirotation screw (42). Install antirotation screw (42) into housing (39).
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   Illustration 4	g01292989

8. Install retaining ring (40) in order to secure turbine end journal bearing (41).
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   Illustration 5	g01293469

9. Install O-ring seal (48) onto the turbine end of housing (39).
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   Illustration 6	g01293010

10. Install compressor end journal bearing (45).
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    Illustration 7	g01293006

11. Install retaining ring (44). Retaining ring (44) secures compressor end journal bearing (45).
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    Illustration 8	g01292998

12. Apply Tooling (T) onto capscrews (42). Use capscrews (42) in order to install major thrust bearing (43).
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    Illustration 9	g01293502

13. Install O-ring seal (49) on the compressor end of bearing housing (50).
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    Illustration 10	g01292984

    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.

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    Illustration 11	g01292981

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    Illustration 12	g01292978

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).
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    Illustration 13	g01292736

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.
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    Illustration 14	g01293558

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.
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    Illustration 15	g01292718

22. Install rotor shaft (31) into the bearing housing. Ensure that the turbine end bearing is not damaged.
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    Illustration 16	g01293566

23. Install Tooling (F) onto gas outlet housing (24).
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    Illustration 17	g01291722

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    Illustration 18	g01293570

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.
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    Illustration 19	g01293587

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.

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    Illustration 20	g01293601

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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    Illustration 21	g01291609

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    Illustration 22	g01291571

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).
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    Illustration 23	g01293625

35. Install Tooling (N) in the bearing housing in preparation for fitting labyrinth seal plate (27).

36. Install labyrinth seal plate (27).
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    Illustration 24	g01291462

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).
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    Illustration 25	g01293610

40. Apply four large spots of Tooling (W) onto the surface of the seal plate.
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    Illustration 26	g01291460

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

    Note: The following steps are for the installation of the impeller.

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    Illustration 27	g01293618

42. Apply Tooling (V) onto rotor shaft (31) and the threads.
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    Illustration 28	g01293705

43. Remove piston ring (52) from impeller (20). Replace piston ring (52) on impeller (20) after the impeller has been cleaned.
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    Illustration 29	g01293711

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.
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    Illustration 30	g01291455

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    Illustration 31	g01291454

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.
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    Illustration 32	g01293732

    1. Compressor housing (11) can be sealed with an O-ring seal (53).
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       Illustration 33	g01293750

    2. 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.
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    Illustration 34	g01293791

49. Install Tooling (H) and Tooling (J) in order to tighten the impeller to the correct torque.
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    Illustration 35	g01293807

50. Install Tooling (K) in order to achieve the proper torque.
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    Illustration 36	g01293843

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).
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    Illustration 37	g01293817

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.
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    Illustration 38	g01293825

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.
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    Illustration 39	g01293848

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:

    1. Ensure that the rotor is pushed toward the compressor end. This removes the rotor thrust clearance.

    2. 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.
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    Illustration 40	g01293865

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 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.
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    Illustration 41	g01293875

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.
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    Illustration 42	g01293889

70. Install bolts (13) and install the lock washers. Tighten bolts (13). Remove Tooling (C).
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    Illustration 43	g01293893

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).
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    Illustration 44	g01293900

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.

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    Illustration 45	g01293923

74. Place nozzle (10) into the housing for turbine inlet (5).
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    Illustration 46	g01291012

75. Place clamping ring (9) onto the nozzle. Align the holes.
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    Illustration 47	g01293935

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).
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    Illustration 48	g01293938

77. Install seal (7) onto the housing for turbine inlet (5).
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    Illustration 49	g01293939
    Typical Example

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).
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    Illustration 50	g01293945
    Typical Example

79. Use the spacers and nuts (6) in order to fasten the housing for turbine inlet (5) to gas outlet housing (24).
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    Illustration 51	g03859429

80. Install a new gasket (4).
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    Illustration 52	g03859410

81. Using two people, install exhaust adapter (2) to turbo (1). The weight of exhaust adapter (2) is approximately 35 kg (77 lb). Apply Tooling (V) to threads of bolts (3) and install bolts (3).

    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.