Disassembly And Assembly Of The Napier NA 297 Turbocharger{1052} Caterpillar

Engine:

3606 (S/N: 8RB)

G3606 (S/N: 3XF)

3608 (S/N: 6MC; 8LL; 7WR)

G3608 (S/N: 4WF)

3612 (S/N: 9RC; 2NZ)

G3612 (S/N: 1YG)

3616 (S/N: 1PD; 1FN)

G3616 (S/N: 4CG)

3618 (S/N: 2MW)

Introduction

This Special Instruction provides the procedures for the proper disassembly and assembly of the 147-8470 Turbocharger . The entire instruction should be read and understood before beginning any work on the engine.

Note: The turbocharger that is in the pictures that follow has already been removed from the engine for photographic purposes.

Disassembly

Preparation For Disassembly

Before the start of the disassembly, mark the position of all the casing flanges and connections in order to be certain that all the components are returned to the correct positions.

• 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.

Disassembly Procedure

Removal Of The Turbocharger From The Engine

1. Disconnect the connections to the turbine inlet.

2. Disconnect the turbine water wash injectors, if equipped.

3. Fit a suitable lifting device to the turbocharger's lifting points at the bearing housing and the gas outlet housing.

4. Take the weight of the turbocharger.

5. Remove the two bolts from the turbine end's mounting foot. Use the 178-0193 Torque Adapter .

6. Remove the four main mount bolts.

   Note: Ensure that the turbocharger remains level during the removal. Use the 178-0196 Torque Adapter .

7. Remove the turbocharger from the engine.

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Illustration 1	g00500094

8. Mount the turbocharger on a suitable service platform.

   Note: Ensure that the turbocharger is mounted securely before more work is performed. Damage may occur if the turbocharger is not mounted properly.

Removal And Disassembly Of The Turbine Inlet Housing And Nozzle

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Illustration 2	g00500098

1. Remove the cotter pins from the six latches that hold the insulation in place.

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Illustration 3	g00500120

2. Remove the insulation.

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Illustration 4	g00500121

3. Remove the twelve nuts, and remove the spacers that secure the turbine inlet housing.

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Illustration 5	g00500122

4. Fit a suitable lifting strap to the turbine inlet housing.

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Illustration 6	g00500123

5. Remove the turbine inlet housing and the seal. The weight of the turbine inlet housing is approximately 35 kg (77 lb).

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Illustration 7	g00500126

6. Remove the six capscrews and the lock washers from the nozzle's clamping ring.

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Illustration 8	g00500129

7. Remove the nozzle's clamping ring.

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Illustration 9	g00500132

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Illustration 10	g00500134

8. Remove the nozzle.

   Note: The serial number, the part number, and the total area of the blades are marked on the nozzle. See Illustration 10.

Disassembly Of The Turbocharger Cartridge

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Illustration 11	g00500136

1. Attach a lifting sling to the turbocharger.

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Illustration 12	g00500139

2. Attach the 177-9781 Lifting Bracket to the compressor insert.

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Illustration 13	g00500162

3. Attach a suitable lifting device to the lifting tool.

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Illustration 14	g00500163

4. Remove two bolts from opposite sides of the compressor insert.

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Illustration 15	g00500165

5. Install the 177-9852 Guide Rod in the compressor insert. Remove the remaining six bolts.

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Illustration 16	g00500170

6. Remove the gland nut for the speed sensor and the rubber grommet.

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Illustration 17	g00500176

7. If necessary, use the three jacking screws in order to loosen the compressor insert.

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Illustration 18	g00500178

8. Remove the compressor insert and the peelable gasket. 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 19	g00500200

9. When the compressor insert is completely out of the compressor housing, withdraw the speed sensor.

10. Stow the speed sensor in a safe place.

11. Remove the guide posts.

Removal Of The Impeller

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 20	g00500201

1. Position the 177-9791 Shaft Locking Tool onto the turbine. Attach the tool with two spacers and nuts.

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Illustration 21	g00500202

2. Install the 177-9795 Socket onto the nose of the impeller. Lock the tool into position with the bolt and with the nut.

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Illustration 22	g00500221

3. Install the 177-9800 Brace onto the compressor housing.

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Illustration 23	g00500223

4. Install the 46 mm socket onto the removal tool.

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Illustration 24	g00500224

5. Install the 6 to 1 6V-7820 Torque Multiplier onto the socket.

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Illustration 25	g00500225

6. Loosen the impeller in the counterclockwise direction.

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Illustration 26	g00500226

7. Remove the impeller.

Removal Of The Compressor Housing

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Illustration 27	g00500227

1. Ensure that the three safety bolts that connect the bearing housing to the gas outlet housing are securely in place. Remove the twelve through bolts.

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Illustration 28	g00500230

2. Attach an 4C-8359 Eyebolt to the compressor housing. Use a suitable lifting device in order to take the weight of the compressor housing.

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Illustration 29	g00500232

3. Remove the three safety bolts that connect the bearing housing to the compressor housing.

4. Screw in the jacking screws evenly until the compressor housing is free.

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Illustration 30	g00500234

5. Remove the compressor housing from the bearing housing.

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Illustration 31	g00500235

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Illustration 32	g00500237

6. Use a 6 mm allen wrench in order to remove the diffuser packing ring.

Disassembly Of The Bearing Housing

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Illustration 33	g00500238

1. Remove the diffuser from the bearing housing. Remove the epoxy adhesive from the area behind the diffuser. Use a ScotchBrite cleaner.

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Illustration 34	g00500239

2. Remove two of the capscrews from the labyrinth seal plate.

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Illustration 35	g00500265

3. Install two 177-9809 Guide Rods into the labyrinth seal plate. Remove the remaining capscrews from the plate.

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Illustration 36	g00500268

4. Install three jacking screws in order to loosen the labyrinth seal plate.

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Illustration 37	g00500270

5. Remove the labyrinth seal plate.

6. Remove the guide posts.

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Illustration 38	g00500272

7. Remove two of the capscrews from the housing of the compressor end bearing.

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Illustration 39	g00500275

8. Install the 177-9809 Guide Rods . Remove the remaining capscrews from the housing of the compressor end bearing.

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Illustration 40	g00500277

9. Use the jacking screws in order to loosen the housing of the compressor end bearing .

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Illustration 41	g00500278

10. Remove the housing of the compressor end bearing.

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Illustration 42	g00500279

11. Remove the guide posts and remove the oil tube.

    Note: The oil tube may still be attached to the housing of the turbine end bearing.

Removal Of The Rotor Shaft

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Illustration 43	g00500201

1. Ensure that the 177-9791 Locking Tool is installed.

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Illustration 44	g00500302

2. Thread the 177-9811 Removal Tool onto the rotor shaft and onto the thrust collar.

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Illustration 45	g00500303

3. Use the four capscrews in order to lock the thrust collar's removal tool in position.

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Illustration 46	g00500305

4. Use a 30 mm wrench and the tooling in order to pull the thrust collar off the shaft.

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Illustration 47	g00500307

5. Remove the tooling with the thrust collar.

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Illustration 48	g00500309

6. Remove the thrust collar from the tooling.

   Note: Ensure that the thrust collar is stored correctly in order to avoid damage to the face.

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Illustration 49	g00500310

7. Remove the shaft locking tool.

8. Support the compressor end of the rotor shaft before the removal of the shaft. This will help to prevent damage to the turbine end bearing.

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Illustration 50	g00500312

9. Remove the rotor shaft from the turbine end.

   Note: The rotor shaft should be stored in a safe area.

Continued Disassembly Of The Bearing Housing

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Illustration 51	g00500741

1. Install two 4C-8359 Eyebolts to the gas outlet housing. Attach a suitable lifting device to the eyebolts.

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Illustration 52	g00500744

2. Remove the three safety bolts from the housing.

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Illustration 53	g00500745

3. Use jacking screws in order to free the gas outlet housing from the bearing housing.

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Illustration 54	g00500746

4. Remove the gas outlet housing.

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Illustration 55	g00500748

5. Remove the six capscrews that secure the cone to the bearing housing.

   Note: The cone is heavy. The cone must be supported when you remove the capscrews.

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Illustration 56	g00500749

6. Remove the cone.

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Illustration 57	g00500750

7. Remove the six capscrews which secure the housing of the turbine end bearing.

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Illustration 58	g00500752

8. Use jacking screws in order to remove the housing.

Removal Of The Bearing (Turbine End)

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Illustration 59	g00500753

1. Remove the retaining ring that secures the turbine end journal bearing.

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Illustration 60	g00500754

2. Remove the antirotation screw from the turbine end's bearing housing.

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Illustration 61	g00500755

3. Remove the turbine end journal bearing.

Removal Of The Bearing (Compressor End)

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Illustration 62	g00500756

1. Remove the six capscrews that secure the major thrust bearing.

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Illustration 63	g00500847

2. Remove the major thrust bearing.

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Illustration 64	g00500853

3. Carefully remove the retaining ring on the compressor end journal bearing.

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Illustration 65	g00500854

4. Remove the compressor end journal bearing.

Assembly

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 66	g00500855

3. Replace the O-ring Seal on the alternate oil manifold.

4. Fit the alternate oil manifold by using the 4 capscrews.

Preparation Of The Bearing Housings (Turbine End & Compressor End)

1. Fit the drain plug to the housing of the turbine end bearing.

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Illustration 67	g00500755

2. Fit the turbine end bearing into the turbine end's bearing housing.

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Illustration 68	g00500754

3. Fit the antirotation screw to the turbine end's bearing housing. Use 7M-7456 Compound on the threads.

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Illustration 69	g00500753

4. Fit the bearing's retaining ring to the turbine end's bearing housing.

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Illustration 70	g00500856

5. Fit a new O-ring Seal to the turbine end's bearing housing.

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Illustration 71	g00500854

6. Install the compressor end journal bearing.

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Illustration 72	g00500853

7. Install the bearing retaining ring to the compressor end's bearing housing.

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Illustration 73	g00500756

8. Use the capscrews in order to install the thrust bearing. Use 7M-7456 Compound on the threads.

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Illustration 74	g00500857

9. Fit a new O-ring seal on the compressor end's bearing housing.

Assembly Of The Bearing Housing

1. Install the housing of the turbine end bearing into the bearing housing. One hole is offset in order to ensure that the oil feed is at the bottom.

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Illustration 75	g00500750

2. Install the six capscrews to the bearing housing. Use 7M-7456 Compound on the threads. Tighten the screws to a torque of 40 N·m (30 lb ft).

   Note: The lock washers are assembled in pairs. Ensure that the mating teeth fit together.

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Illustration 76	g00500858

3. Fit the cone to the bearing housing by using the 6 capscrews and lock washers. Tighten the screws to a torque of 50 N·m (37 lb ft).

   Note: A 5P-3931 Anti-Seize Compound should be used on the threads of the screws.

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Illustration 77	g00500744

4. Install the gas outlet housing to the bearing housing.

5. Fit the three safety bolts that connect the bearing housing to the gas outlet housing.

Preparation Of The Rotor Shaft

1. Ensure that the rotor is balanced.

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Illustration 78	g00500925

2. Install two piston ring seals onto the turbine end of the shaft. Use the 1U-6683 Ring Expander . Ensure that there is 180 degrees between the gaps.

3. Lubricate the piston ring seals and the turbine end bearing with clean engine oil.

Installation Of The Rotor Shaft

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Illustration 79	g00500312

1. Install the shaft assembly into the bearing housing. Ensure that the turbine end bearing is not damaged.

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Illustration 80	g00500201

2. Install the 177-9791 Locking Tool on the gas outlet housing.

3. Apply 5P-3931 Anti-Seize Compound on the thrust collar's position on the shaft.

4. Heat the thrust collar to approximately 100°C (212°F).

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Illustration 81	g00500927

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Illustration 82	g00500930

5. While the shaft is pushed completely toward the compressor end, fit the thrust collar on the shaft. Use the 177-9811 Tool in order to ensure that the thrust collar is fully seated.

6. When the thrust collar has cooled for approximately 15 minutes, remove the tooling.

   Note: If it is not possible to heat the thrust collar, the collar can be pushed onto the shaft by using the tooling.

Installation Of The Housing Of The Compressor End Bearing

1. Fit three new O-ring Seals to the oil tube.

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Illustration 83	g00500279

2. Install the oil tube with two O-rings into the turbine end's bearing housing.

3. Liberally oil the thrust bearing and journal bearing with clean engine oil.

4. Install the 177-9852 Guide Rods in the bearing housing in preparation for fitting the compressor end's bearing housing.

   Note: Ensure that the oil tube is correctly aligned.

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Illustration 84	g00500278

5. Install the compressor end's bearing housing to the bearing housing.

6. Remove the guide posts.

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Illustration 85	g00500272

7. Install the 6 capscrews. Tighten the screws to a torque of 40 N·m (30 lb ft). Use 7M-7456 Compound on the threads of the screws.

Continued Preparation Of The Bearing Housing

1. Install the 177-9809 Guide Rods in the bearing housing in preparation for fitting the labyrinth seal plate.

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Illustration 86	g00500270

2. Install the labyrinth seal plate.

3. Remove the guide posts.

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Illustration 87	g00500239

4. Install the 6 capscrews. Tighten the screws to a torque of 40 N·m (30 lb ft). Use 7M-7456 Compound on the threads of the screws.

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Illustration 88	g00500932

5. Apply four large spots of the 8T-9022 Silicone Gasket to the seal plate's surface.

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Illustration 89	g00500238

6. Install the diffuser on the bearing housing.

Installation Of The Impeller

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Illustration 90	g00500933

1. Apply 5P-3931 Anti-Seize Compound on the rotor shaft and the threads.

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Illustration 91	g00500937

2. Remove the piston ring from the impeller. Replace the piston ring on the impeller after the impeller has been cleaned.

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Illustration 92	g00500961

3. Install the impeller on the shaft. Gently turn the impeller by hand until the impeller is tight.

4. 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 93	g00500237

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Illustration 94	g00500235

5. Install the diffuser packing ring on the compressor housing by using the capscrew.

6. 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 95	g00501091

   1. The compressor housing can be sealed with an O-ring seal.
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   Illustration 96	g00501092

   2. The compressor housing can be sealed by using the 8T-9022 Silicone Gasket .

      Note: These two methods are not interchangeable.

7. Fit the compressor housing to the bearing housing. Attach the three safety bolts. Fit the spring washers and nuts.

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Illustration 97	g00500223

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Illustration 98	g00500224

8. Fit the 177-9800 Brace and fit the 177-9795 Socket in order to tighten the impeller to the correct torque.

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Illustration 99	g00500225

9. Tighten the impeller to a torque of 610 N·m (450 lb ft). Use the 6V-7820 Torque Multiplier .

10. Remove the tooling that was installed in Step 8.

11. Remove the shaft locking tool.

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Illustration 100	g00501093

12. Mount a 7H-1942 Dial Indicator to the gas outlet housing. This dial indicator is a part of the 8T-5096 Dial Indicator Group . Position the tip of the gauge to the turbine.

13. Push the rotor toward the turbine end. Hold the rotor in place. Zero the indicator.

14. 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.

Assembly Of The Compressor Insert

1. Install the 177-9809 Guide Rods to the compressor housing in the preparation for fitting the insert.

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Illustration 101	g00501095

2. Attach the 177-9781 Lifting Bracket to the compressor insert.

3. Position the compressor insert onto the guide posts.

   Note: Use extreme caution when you are pushing the insert into the compressor housing. Damage to the impeller could occur. The insert must be kept level.

4. Push the insert into the compressor housing.

5. Ensure that the gap between the insert and the compressor housing is equal.

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Illustration 102	g00501098

6. Use feeler gauges in order to measure the gap in four places. Take the average of the measurements. Record this dimension.

7. 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 6. 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).

8. Peel off the laminations of the shim until the correct thickness is achieved.

9. Remove the eight capscrews. Remove the compressor insert with extreme caution.

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Illustration 103	g00501160

10. Fit the O-ring seal to the compressor insert. Moderately lubricate the O-ring seal.

11. Screw the speed sensor into the compressor insert until the end of the 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.

12. Fit the shim onto the guide posts.

13. Feed the wiring for the speed sensor through the hole in the compressor housing.

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Illustration 104	g00501167

14. Install the compressor insert into the compressor housing. Ensure that the insert remains level in order to avoid damage to the impeller. Ensure that the wire for the speed sensor does not get trapped.

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Illustration 105	g00500163

15. Install the eight capscrews and install the lock washers. Tighten these capscrews. Remove the lifting bracket.

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Illustration 106	g00501163

16. Tighten the locknut on the speed sensor.

17. Use a feeler gauge in order to measure the gap from the tip of an impeller vane to the compressor insert. This measurement should be taken next to the speed sensor.

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Illustration 107	g00501165

18. Use a feeler gauge in order to measure the gap from the tip of an impeller vane to the compressor insert. This measurement should be taken at the speed sensor. If the reading is different from Step 17, adjust the speed sensor.

Installation Of The Gas Inlet Housing

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Illustration 108	g00500132

1. Place the nozzle into the gas inlet housing.

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Illustration 109	g00500129

2. Place the clamping ring onto the nozzle. Align the six holes.

3. Install the six capscrews and lock washers. Tighten the screws to a torque of 67 N·m (49.5 lb ft).

   Note: Use 5P-3931 Anti-Seize Compound on the threads of the screws.

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Illustration 110	g00501169

4. Fit the C-ring seal on the gas inlet housing.

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Illustration 111	g00500123

5. Use a suitable lifting device in order to place the gas inlet housing on the gas outlet housing.

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Illustration 112	g00500121

6. Use the spacers and the nuts in order to fasten the gas inlet housing to the gas outlet housing.

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Illustration 113	g00500120

7. Install the insulation.

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Illustration 114	g00500098

8. Insert the cotter pins in the six latches that hold the insulation in place.

Installation Of The Turbocharger On The Engine

1. 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.

2. Install the two main bolts in the mounting foot. Tighten the bolts to a torque of 420 N·m (310 lb ft). Use the 178-0193 Torque Adapter .

3. Install the four main mounting bolts with the 178-0196 Torque Adapter .

4. Connect the turbine inlet connections.

5. Connect the speed sensor connection.

6. Connect the turbocharger wash group, if equipped.

7. Reconnect the instrumentation.

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

Removal And Installation Of The Turbocharger Cartridge

Removal Of The Turbocharger Cartridge

Note: Before you remove the cartridge, the gas outlet housing must be supported. Severe damage will occur to the housing and the turbine if the housing is not secured.

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Illustration 115	g00500120

1. Remove the insulation from the turbocharger.

2. Disconnect the speed sensor connection.

3. Disconnect the turbocharger wash group, if necessary.

4. Remove the alternate oil drain line, if necessary.

5. Disconnect the alternate oil feed, if necessary.

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Illustration 116	g00501170

6. Attach a suitable lifting device to the bearing housing.

7. Remove the three safety bolts that connect the bearing housing and the gas outlet housing.

8. Remove the nuts and washers that connect the compressor housing and the gas outlet housing.

9. Take the weight of the turbocharger with the lifting device.

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Illustration 117	g00501171

10. Remove the four mounting bolts.

    Note: Ensure that the cartridge remains level. Damage may occur if the cartridge does not remain level.

    Note: Jacking screws may be used in order to remove the cartridge from the gas outlet housing.

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Illustration 118	g00501173

11. Remove the cartridge from the gas outlet housing.

    Note: The nozzle may be removed from the compressor end.

Removing The Nozzle From The Compressor End

1. Remove two capscrews and lock washers from the shroud assembly.

2. Remove the four remaining capscrews and lock washers from the shroud assembly. Remove the shroud assembly.

3. Remove the six capscrews and lock washers that secure the nozzle.

4. The nozzle can now be removed, cleaned, and inspected for damage.

Installation Of The Nozzle From The Compressor End

1. Place the nozzle into the gas inlet housing.

2. Place the clamping ring onto the nozzle. Align the six holes.

3. Install the six capscrews and lock washers in the clamping ring. Tighten the screws to a torque of 67 N·m (49.5 lb ft).

   Note: Use 5P-3931 Anti-Seize Compound on the threads.

4. Fit the shroud to the gas outlet housing.

5. Install the six capscrews and lock washers in the shroud. Tighten the screws to a torque of 30 N·m (22 lb ft).

Installation Of The Turbocharger Cartridge

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Illustration 119	g00501173

Note: The following paragraph relates to the front turbocharger only. If the cartridge is being assembled to the gas outlet housing on the engine, be sure to properly position the O-Ring seal. This seal is placed on the oil drain on the turbocharger support. (Later designs eliminate the O-Ring seal and these engines use a tube that is inserted into the turbocharger support.) When you replace a cartridge, be sure that the proper cover is removed from the oil drain hole. The other drain holes must remain plugged.

1. Fit the cartridge assembly in the gas outlet housing.

2. Install the four mounting bolts. Tighten the bolts to a torque of 492 N·m (365 lb ft).

3. Install the nuts and washers on the studs on the gas outlet housing. Install the three safety bolts.

4. Install the alternate oil drain line, if necessary.

5. Connect the alternate oil feed, if necessary.

6. Connect the turbocharger wash group, if necessary.

7. Connect the speed sensor connection.

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Illustration 120	g00500120

8. Install the insulation.