Installation Instructions for Turbochargers {1052} Caterpillar

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Introduction

This special instruction provides the instructions for the installation of the turbocharger. Turbochargers are sensitive to contamination. This special instruction provides information on the acceptability of cracks that are in the turbine housing. Failure to follow any of the procedures may result in damage, a malfunction, or possible engine failure.

The following items have been made available to help reduce premature Turbocharger failure due to contamination.

• An instruction manual for turbocharger failures has also been published to assist in diagnosing turbocharger failures. The document is Special Instruction, SEBF9085, "Failure Modes of Turbochargers".

General

1. Clean the area around the turbocharger to remove potential contaminants.

2. Examine the turbocharger for potential causes of failure.

   1. Examine the exhaust system and the exhaust manifold to ensure that no foreign material is present.

   2. Examine the air cleaner, the aftercooler, and the ducting to ensure that no foreign material is present.

   3. If there is any sign of oil on the compressor side, inspect the accumulator/oil separator and the aftercooler.
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   NOTICE
   Oil that is left in the Air-To-Air Aftercooler can result in engine overspeed.

3. Work in an enclosed area or use tarps to minimize the entrance of airborne debris.

4. The bolts in the turbochargers may be intentionally left loose to facilitate the installation. Extra bolts may be required.

   Note: Turbochargers are carefully inspected and the components are compared to functional specifications. Upon visual inspection of turbochargers, you may find cracks in the wall that divides the turbine housing. On turbochargers, cracks are allowed along the radius of the wall that divides the turbine housing. Refer to Reuse And Salvage Guidelines, SEBF8018, Visual Inspection of Turbochargers for more information.

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   Illustration 1	g03476245
   (1) Cracks in the divider wall

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   Illustration 2	g03476249
   (1) Cracks in the divider wall

5. The turbine housing is designed to relieve thermal stress. The thermal stress is created by high exhaust temperature and relieved through cracks in the turbocharger divider wall (1). The cracks in the divider wall (1) will not affect operation of the turbocharger.

Turbocharger Removal

Complete the following before you remove the turbocharger from the engine.

1. When the V-band clamps are correctly positioned, tighten the nuts of the V-band clamp to the specified torque. Gently tap around the clamp the clamps. Tighten the clamps again to the specified torque.

2. Tighten the bolts alternately to the recommended torque to prevent and cocking of the housings and damage to the housing and wheels.

Note: Refer to the Specifications, "Turbocharger" in SIS (Directions in Additional Information section), the Operation and Maintenance Manual, or your dealer for torque values and additional information.

Installation and Prelubing of the Turbocharger

1. Remove the old gasket from the mount of the exhaust manifold. Inspect the flange for cracks, erosion, and flatness. If necessary, replace the exhaust manifold.

   Note: If installing only a cartridge, inspect the existing turbine and compressor housings for damage on the mating surfaces and the internal contours.

2. Clean the passages from the engine exhaust manifold and the passages from the air filter to the turbocharger.

   Note: Do NOT connect the compressor inlet and the oil supply line.

3. Install the turbocharger on the engine with all new gaskets and O-ring seals.

4. Tighten the bolts that attach the turbocharger to the exhaust manifold to the torques specified in the Service Manual or the Operation and Maintenance Manual.

   Note: Use 5P-3931 Anti-Seize Compound on the nuts and threads before installation.

Realignment Of End Housings

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NOTICE
The correct procedures and tooling specifications must always be used. Failure to follow any of the procedures may result in damage, malfunction, or possible engine failure.

Note: Excessive loosening of the housings will cause contact between the internal components of the turbocharger. Possible damage to the turbine wheel may occur.

1. Loosen the bolts for the turbocharger compressor housing and the bolts for the turbocharger turbine housing, and/or loosen the nuts on the V-band clamp.

2. Temporarily secure the turbocharger to the output flange of the engine exhaust manifold. Ensure that the bolts are snug.

3. Rotate the center housing so that the oil inlet and outlet port will mate with the turbochargers oil supply and drain line. The oil outlet must be at the bottom.

   Note: If the turbocharger has a drain tube, use the drain tube to verify proper orientation of the bearing housing. The drain tube should be installed so that there is no binding of the tube after the installation. For turbochargers without a drain tube, the centerline of the hole must not be more than 35 degrees from vertical.

4. Tighten at least two of the bolts or the V-band clamp to lock the center housing to the turbine housing.

   Note: If there is an O-ring on the backplate that seals against the compressor housing make sure that the O-ring is seated and installed correctly before orienting the housing. Rotating or clamping the housing in place while the seal is not seated correctly could lead to a premature failure.

5. Rotate the compressor housing until the housing lines up with the intake manifold or the aftercooler outlet line. Tighten at least two of the bolts or the V-band clamp to the specified torque with the correct procedure to lock the housing in place.

   Reference: Refer to the Specification, "Turbochargers", and the Operation and Maintenance Manual for torque values and additional information.

6. Bend the locking tabs upward against a flat surface on each bolt head if there is a bolted housing. Bend the locking tabs in a direction which will tighten the bolt. The nuts of the V-band are self-locking.

7. Attach the drain line and refill the oil inlet with clean oil. Connect the oil supply line. Tighten the oil drain and supply lines to the specified torques. Refer to the "Additional Information" section to locate these torque values.

   Note: If the compressor or turbine wheel CANNOT be spun freely or if there is any rubbing, the reason MUST be determined and corrected BEFORE you start the engine. End housings that are not properly seated on the cartridge housing may cause rubbing.

8. If the compressor wheel spins freely, connect the pipe from the outlet of the air filter to the inlet of the compressor. Tighten the connections to the torques that are specified in theSpecification, "Turbocharger" or the Operation and MaintenanceManual.

9. If the turbine wheel spins freely, connect the exhaust outlet to the turbine housing. Tighten the connections to the torques that are specified in theSpecification, "Turbocharger" or the Operation and MaintenanceManual.

   Note: If debris is found on the oil bypass valve, the oil pan must be removed and any debris must be cleaned from the oil pan. If the remaining debris is not removed, the oil bypass valve will be recontaminated upon start-up.

10. Perform the following procedures to the oil bypass valve:

    1. Remove the oil bypass valve.

    2. Inspect and clean the oil bypass valve.

    3. Reinstall the oil bypass valve.

11. If debris is found during Step 9 or if the previous turbocharger experienced a failure, CHANGING THE ENGINE OIL AND THE FILTER OR FILTERS IS REQUIRED.

12. Check the oil in the engine crankcase.

Starting The Engine

1. Start the engine. Allow the engine to run at low idle until the engine reaches operating temperature.

2. Inspect the turbocharger for oil leaks.

3. Take an oil sample.

Additional Information

Reference: Refer to Specifications, "Turbocharger" in SIS, the Operation and Maintenancemanual or your dealer for torque values and additional information.

Directions for obtaining torque values and procedures for turbocharger housing connections using SIS web:

1. Navigate to the SIS website.

2. Enter the engine serial number prefix.

3. Select "Systems and Components".

4. Select "Air Inlet and Exhaust System".

5. Select "Turbocharger Gp".

6. Select "Specifications".

7. Select the page with the corresponding part number.

Directions for obtaining special oil supply and drain bolt torque values using SIS web:

1. Navigate to the SIS website.

2. Enter the engine serial number prefix.

3. Select "Systems and Components".

4. Select "Air Inlet and Exhaust System".

5. Select "Turbocharger Gp".

6. Select "Specifications" and/or "Disassembly and Assembly".

If torque values for the turbocharger oil supply and drain bolts do not appear in the "Specifications" and/or "Disassembly and Assembly" manual, refer to Torque Specifications, SENR3130 for general torque values.

Directions for obtaining generic oil supply and drain bolt torque values using SIS web:

1. Navigate to the SIS website.

2. Enter the engine serial number prefix.

3. Select "Documentation".

4. Select "Torque Specifications".

5. Select the section based on the type of bolt or nut.