Specifications and Rebuilding Procedure for TPS-61, TPS-57, TPS-52, TPC-49, TPC-47, TPS-48, and TPS-44 Type ABB Turbochargers for 3500 Engines{1052, 1065} #i03894779 Caterpillar


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Usage:

793B 1HL   785C 1HW   854G 1JW   3512 1LM   3516B 1NW   3512B 1PW   3508B 1TW   3508 1ZF   3508 23Z   3512 24Z   3516 25Z   3516 27Z   3516 28Z   3512 2AF   3508B 2BM   789C 2BW   3512B 2EZ   3516B 2FW   3508B 2GR   3512B 2GW   3508B 2HW   G3508 2JF   3516B 2JW   3516 2PK   784C 2PZ   G3508 2TJ   776C 2TK   3516 2TS   3512 2WK   777D 2YW   3516B 3CW   3508B 3DM   3508B 3DW   3508 3HM   3516 3JS   3508B 3LS   3512 3MS   3516B 3NS   777D 3PR   3508 3PS   G3516 3RC   3512 3RS   793 3SJ   994D 3TZ   3516B 3XS   3512 3YF   3512B 3ZW   994F 442   3512 49Y   793C 4AR  


Engine: All 3500 Engines

Introduction

Table 1
Revision     Summary of Changes in SEBF9207    
09     Added new serial number prefixes.    
08     Added Tables 3, 4, 9, and 10.
Added Specifications for TPS 44, TPC 47, and TPC 49 Turbochargers in Table 5    
07     Updated Effectivity
Updated Safety Section    
06     Updated Effectivity
Added safety information    
05     Updated to include information for TPS-52 Type Turbochargers    
01 - 04     Updated Effectivity    

© 2014 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information in order to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made in order to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. In order to address an urgent issue, use the following resources in order to communicate your request to Caterpillar Repair Process Engineering:

  • Caterpillar Dealer Technical Communicator

  • Dealer Solution Network

  • Caterpillar Technical Representative

  • Knowledge Network

Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information




Illustration 1g02139237

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method or operating technique that is not specifically recommended by Caterpillar is used, you must ensure that it is safe for you and for other people to use. You should ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance or the repair procedures that are used.

------ WARNING! ------

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

----------------------

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the safety alert symbol which is followed by a signal word such as danger, warning, or caution. The "WARNING" safety alert symbol is shown below.




Illustration 2g00008666

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. You must determine that the tools, procedures, work methods, and operating techniques are safe. You must determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, you must determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

References

ReferenceRefer to Reuse and Salvage Guidelines, SEBF8018, "Visual Inspection of Turbochargers" for more information.

ReferenceRefer to Reuse and Salvage Guidelines, SEBF8403, "Reuse Specifications for ABB housing/">Housings on 3500 Engines" for more information on allowable cracks in compressor housings and turbine housings.

ReferenceRefer to Disassembly and Assembly, SENR5535, "Turbocharger - Disassemble" for more information on the disassembly procedure for the TPS-57 turbocharger. The other models covered in this document are similar.

ReferenceRefer to Disassembly and Assembly, SENR5535, "Turbocharger - Assemble" for more information on the assembly procedure for the TPS-57 turbocharger. The other models covered in this document are similar.

Basic Disassembly Procedure

Table 2
Required Tooling    
Tooling Number     Part Number     Quantity     Description    
A     -     2     Jack Screw    
B     FT-2685     1     Service Stand    
C     -     1     Thread Protector    

Turbocharger and Turbocharger Component Weights

Use the following chart for weights of the turbocharger and it's individual components.




Illustration 3g03550741

Table 3
Turbocharger Component Weights    
    TPS 44     TPS 48     TPS 52     TPS 57     TPS 61    
Turbocharger Weight     85 kg (187 lb) (1)    
110 kg (243 lb) (1)    

160 kg (353 lb) (1)    

260 kg (573 lb) (1)    

450 kg (992 lb) (1)    
Compressor housing/">Housing (1)    
17 kg (38 lb)    

24 kg (53 lb)    

35 kg (77 lb)    

51 kg (112 lb)    

89 kg (196 lb)    
Insert Wall (2)    
4 kg (9 lb)    

7 kg (15 lb)    

10 kg (22 lb)    

13 kg (29 lb)    

30 kg (66 lb)    
Diffuser (3)    
2 kg (4 lb)    

2 kg (4 lb)    

3 kg (7 lb)    

6 kg (13 lb)    

10 kg (22 lb)    
Cartridge Group (4)    
25 kg (55 lb)    

35 kg (77 lb)    

55 kg (121 lb)    

85 kg (187 lb)    

140 kg (308 lb)    
Turbine Casting with External Rupture Protection (5)     1 Inlet    
28 kg (62 lb)    

32 kg (71 lb)    

47 kg (104 lb)    

77 kg (170 lb)    

130 kg (287 lb)    
2 Inlets
30 kg (66 lb)    

35 kg (77 lb)    

50 kg (110 lb)    

86 kg (190 lb)    

145 kg (320 lb)    
3 Inlets        
53 kg (117 lb)    

93 kg (205 lb)    

162 kg (357 lb)    
4 Inlets            
93 kg (205 lb)    

162 kg (357 lb)    
Rupture Ring (6)    
1 kg (2 lb)    

2 kg (4 lb)    

3 kg (7 lb)    

5 kg (11 lb)    

12 kg (26 lb)    
Nozzle Ring (7)    
1 kg (2 lb)    

1 kg (2 lb)    

2 kg (4 lb)    

3 kg (7 lb)    

6 kg (13 lb)    
( 1 ) Does not include weight of any air cleaner piping or exhaust piping.



Illustration 4g03549879

Breakdown of the Cartridge Group.

Table 4
Turbocharger Cartridge Component Weights    
    TPS 44     TPS 48     TPS 52     TPS 57     TPS 61    
Cartridge Group (1)    
25 kg (55 lb)    

35 kg (77 lb)    

55 kg (121 lb)    

85 kg (187 lb)    

140 kg (308 lb)    
Compressor Wheel (2)    
1 kg (2 lb)    

2 kg (4 lb)    

3 kg (7 lb)    

5 kg (11 lb)    

7 kg (15 lb)    
Bearing Cover (3)    
2 kg (4 lb)    

2 kg (4 lb)    

3 kg (7 lb)    

6 kg (13 lb)    

12 kg (27 lb)    
Bearing Parts, Complete (4)    
2 kg (4 lb)    

3 kg (7 lb)    

4 kg (9 lb)    

8 kg (18 lb)    

13 kg (29 lb)    
Bearing Casing (5)    
15 kg (33 lb)    

19 kg (42 lb)    

30 kg (66 lb)    

45 kg (99 lb)    

70 kg (154 lb)    
Partition Wall (6)    
2 kg (4 lb)    

2 kg (4 lb)    

4 kg (9 lb)    

7 kg (15 lb)    

11 kg (24 lb)    
Shaft (7)    
3 kg (7 lb)    

5 kg (11 lb)    

8 kg (18 lb)    

14 kg (31 lb)    

24 kg (53 lb)    

Removing the Cartridge Assembly

Note: Refer to Table 3 and table 4 for the weight of the complete turbocharger and the individual turbocharger components.




Illustration 5g02138341

(1) Cartridge Group

(2) Diffuser

(3) Wall Insert

(4) Compressor housing/">Housing

(5) Nozzle Ring

(6) Rupture Ring

(7) Turbine housing/">Housing

  1. Position the turbocharger assembly onto a suitable work surface.



    Illustration 6g02138413



    Illustration 7g02138460

    Using Tooling (A)

  1. Attach a suitable lifting device to the compressor housing (4). Remove bolts (8) and rings (9). The compressor housing can now be separated from the cartridge assembly.

    Note: Tooling (A) can be used to separate compressor housing (4) from the cartridge assembly, if necessary. Make sure that you apply equal force to each of side of the compressor housing with Tooling (A). This will allow the compressor housing to be removed evenly without damaging other components.

  1. Use a rubber mallet in order to tap wall insert (3) and remove wall insert (3) from the compressor housing. Bolts (8) can be installed into wall insert (3) in order to aid in removal of wall insert (3). Remove O-ring seal (10) and O-ring seal (11), if equipped.



    Illustration 8g02139115

  1. Remove sensor (14). Attach a suitable lifting device to the cartridge group (1). Remove the nuts (13) and the rings (12) from the turbine housing and remove cartridge group (1).

    Note: Tooling (A) can be used in order to separate the cartridge group (1) from the turbine housing, if necessary.




    Illustration 9g02138616

  1. Remove nozzle ring (5) and sealing ring (15) from the turbine housing.



    Illustration 10g02138633

  1. Use the suitable lifting device in order to place the cartridge assembly (1) onto Tooling (B). Remove screw (17) and remove diffuser (2). Remove O-ring seal (16) .

Checking the Clearances of the Bearings

The clearances of the bearings should be measured before the cartridge assembly is disassembled. This will give a good indication of the bearing life that remains or any unusual wear problems. The turbine should be raised slightly before the axial clearance (A) is measured due to the weight of the turbine shaft.

Table 5
Bearing Clearances    
    TPS 44     TPC 47     TPS 48     TPC 49     TPS 52     TPS 57     TPS 61    
A Minimum    
0.08 mm (0.0032 inch)    

0.08 mm (0.0032 inch)    

0.08 mm (0.0032 inch)    

0.08 mm (0.0032 inch)    

0.10 mm (0.0039 inch)    

0.12 mm (0.0047 inch)    

0.15 mm (0.0059 inch)    
A Maximum    
0.16 mm (0.0063 inch)    

0.16 mm (0.0063 inch)    

0.16 mm (0.0063 inch)    

0.16 mm (0.0063 inch)    

0.18 mm (0.0070 inch)    

0.21 mm (0.0083 inch)    

0.25 mm (0.0098 inch)    
B Minimum    
0.50 mm (0.0197 inch)    

0.37 mm (0.0146 inch)    

0.50 mm (0.0197 inch)    

0.40 mm (0.0158 inch)    

0.61 mm (0.0240 inch)    

0.72 mm (0.0283 inch)    

0.81 mm (0.0319 inch)    
B Maximum     (1 mm)(0.0394 inch)    
0.90 mm (0.0354 inch)    

1 mm (0.0394 inch)    

0.98 mm (0.0386 inch)    

1.15 mm (0.0452 inch)    

1.31 mm (0.0516 inch)    

1.55 mm (0.0610 inch)    



Illustration 11g02138859

Measuring the axial clearance (A) and the radial clearance (B) of the bearings

Disassemble the Cartridge Assembly

Table 6
Part Number     Quantity     Description    
FT-2685     1     Service Stand    
-         Thread Protector    



Illustration 12g02138741

Exploded view of the cartridge assembly




    Illustration 13g02138747

    Removing the Compressor Wheel

  1. Use two opposing wrenches in order to remove compressor wheel (1), as shown.



    Illustration 14g02138750

  1. Install a thread protector (6) over the threads of the turbine shaft and remove two screws (4). Install screws (4) into the tapped holes in bearing cover (3). Use screws (4) as forcing screws in order to remove bearing cover (3). Remove O-ring seal (2). Remove ring (5) .

  1. Remove thread protector (6) and sealing disc (7) .



    Illustration 15g02138751

    Removing the Turbine Shaft and Bearing Assembly

  1. Remove bolts (13). Insert bolts (13) into the tapped holes of bearing assembly (12). Use bolts (13) as forcing screws in order to remove bearing assembly (12) from center housing (11) .

    Note: Make sure that you secure turbine shaft (8) before you remove bearing assembly (12).

  1. Pull turbine shaft (8) from the center housing and remove ring (9). Remove plate (10) .



    Illustration 16g02138752

    Exploded View of the Bearing Assembly




    Illustration 17g02138818

  1. Separate bearing housings (24) and (14). Remove auxiliary bearing (21), thrust bearing (20), and thrust ring (19) .

  1. Remove bolt (22) and remove bearing (23) from bearing housing (24) .

  1. Remove retaining ring (18). Remove bolt (15) and bearing (17). Remove the other retaining ring (16) from bearing housing (14) .

Cleaning Procedures

General




Illustration 18g02085634



Illustration 19g02085635

Improper care of parts during Disassembly and Assembly can cause a future failure of the turbocharger. Inspect the parts for defects in order to be sure that the parts can be used again. Use Magnus 763 N/F or a similar heavy-duty carbon solvent to loosen the carbon from the parts. For the best results, use a small closed tank for cleaning with the solvent. Make sure that the tank is agitated. After the carbon is loosened, use a hard bristle brush and remove all dirt particles. Clean all drilled passages with air under pressure.


NOTICE

Do not use caustic solutions, wire brushes, or wire wheels to remove carbon deposits from any turbocharger part.


Removal of carbon deposits on some parts is difficult with solvent. Those parts can be cleaned with glass beads. Use glass beads (size 10) that are 0.08 mm (0.003 inch) to 0.15 mm (0.006 inch) with 551.6 kPa (80.00 psi) to 620.5 kPa (90.00 psi) air pressure.

Note: There must be no aluminum oxide in the glass beads.

Some turbocharger parts must be polished with 266-3452 Emery Polishing Paper . Turbocharger parts that are cleaned with glass beads or polished with emery polishing paper must be cleaned in a solvent before reassembly. Put oil on cleaned parts in order to prevent corrosion.

Turbine Wheels and Shaft Assemblies




Illustration 20g01410053

Typical Example

Masking tape is used on the shaft and the bearing journals for protection from glass beads.




Illustration 21g01410109

Typical Example

Cleaned turbine wheel

Note: Do not allow the glass beads to hit the bearing journals.

The carbon deposits must be removed from the seal ring grooves before the side clearance of the seal ring can be checked. Remove the carbon deposits with a hard bristle brush, a piece of the metal oil seal ring, or glass beads. After the carbon is removed from the seal ring grooves, lightly polish the side walls of the groove with 266-3452 Emery Polishing Paper .

Lacquer and carbon deposits that cannot be removed from the shaft with a heavy-duty carbon solvent and bristle brush can be removed with a Scotch-Brite very fine general-purpose pad. Before the Scotch-Brite pad is used, put a clean, lightweight oil on the surface of the shaft. For best results with the Scotch-Brite pad, turn the wheel and shaft assembly in a lathe.

After the wheel and shaft assembly is cleaned, dry thoroughly with clean moisture free air. Put lightweight oil on the bearing journals and seal surfaces in order to prevent rust and corrosion.

Compressor Wheels




Illustration 22g01410114

Typical Example

Compressor wheel that was cleaned with glass beads


NOTICE

Do not use glass beads on the compressor wheel bore or the mounting faces around the bore. Use tape or plugs to protect this area during glass beading. Thoroughly wash the compressor wheel in solvent after glass beading.


Center housing/">Housing




Illustration 23g01410119

Typical Example

If the glass beads are used to clean the center housings, use plugs that extend into the area of the bore so the plugs are over the complete length of the bearing bore.

To remove some of the carbon deposits on the inside of the center housing, use glass beads through the oil return hole at the bottom of the center housing.


NOTICE

Never assemble a turbocharger before the center housing is thoroughly cleaned with a heavy-duty carbon solvent.


Compressor and Turbine housing/">Housings




Illustration 24g02086376

Typical Example

The critical areas of the compressor housing and the turbine housing are the mounting flanges where the cartridge is attached to the housings. All foreign material should be removed from these areas, as shown.

Inspection Procedure

ReferenceRefer to Reuse and Salvage Guidelines, SEBF8018, "Visual Inspection of Turbochargers" for more information.

ReferenceRefer to Reuse and Salvage Guidelines, SEBF8403, "Reuse Specifications for ABB housing/">Housings on 3500 Engines" for more information on allowable cracks in compressor housings and turbine housings.

Turbine Wheel, Compressor Wheel, and housing/">Housings




Illustration 25g02086289

Typical Example

Small lip on compressor wheel that can be felt with your fingernail

USE AGAIN




Illustration 26g02140582

Removing small burrs

Sometimes, the compressor wheel has a small lip that can be felt with your fingernail. This is caused from a small amount of rubbing against the compressor housing. This part can be used again, after the compressor wheel is cleaned and media blasted. Small burrs can also be removed with fine grit sandpaper.




Illustration 27g02086290

Typical Example

Slight rubbing in the compressor housing from contact with compressor wheel

USE AGAIN




Illustration 28g02139898

Turbine housing/">Housing

The studs on the turbine housing should always be replaced each time the turbocharger is serviced. The tapped holes in the flange should be inspected for damage. A Heli-Coil can be used to repair damaged threads, if necessary.




Illustration 29g02139901

Turbine housing/">Housing Insert

The turbine housing insert is usually OK to use again. Check the threads of the tapped holes. A Heli-Coil can be used to repair damaged threads, if necessary.




Illustration 30g02139900

Compressor housing/">Housing

The flange of the compressor housing should be inspected for damage. The flange can be welded, if necessary. Belzona can also be used for pitting on the face of the flange if required.




Illustration 31g02139903

Diffuser Ring

The diffuser ring is normally OK to use again. Check the fins for damage and straightness.




Illustration 32g02139906

Seals and Rings

The seals and the rings should ALWAYS be replaced with new. NEVER Reuse the old seals or the old rings.




Illustration 33g02139965

Nozzle Ring

The nozzle ring can be cleaned with plastic media blasting and used again. Check the fins for damage and check the seal groove for damage such as dents or cracks.




Illustration 34g02139981

Compressor Insert

The compressor insert should be cleaned and inspected. Check the internal surface for nicks and scratches. Inspect the seal groove for dents or other damage.

Shaft Bearings

The following table lists guidelines for replacing the bearing. This guideline should only be used if the axial clearances and the radial clearances of the bearing were within specifications. Refer to ""Checking the Clearances of the Bearings" ". If the clearances of the bearings were determined to be at the Maximum limits during inspection, the bearings should be replaced regardless of the condition in order to provide a good service life.

Table 7
Bearing Inspection Guideline    
Description     Observed Damage     Action    
Bearing Surfaces     Parts of Bearing Material Missing     Change Bearings    
Cracks in Bearing Material Change Bearings    
Scored Bearing Surfaces Minor Scratches are Acceptable (1)    
Surfaces are Worn, but in Good Condition Use Bearing Again (2)    
Pitting, Excessive Wear on Bearing Surface, Oil Starvation problem Change Bearings    
( 1 ) NEVER attempt to remove scratches by polishing the bearing
( 2 ) The Bearing MUST be within the specifications that are listed. Refer to ""Checking the Clearances of the Bearings" ".

Turbine Shaft




Illustration 35g01410160

Use 5P-6518 Dial Indicator Fixture Gp to check for bent shafts.




Illustration 36g02139803

Example of a V Block and Dial Indicator

Use the 5P-6518 Dial Indicator Fixture Gp and the following procedure to measure the bend in wheel and shaft assemblies.

Note: A V block and dial indicator can also be used to measure the turbine wheel shaft.

  1. Put the wheel and shaft assembly in 5P-6518 Dial Indicator Fixture Gp so the bearing journals are on the vee blocks.

    Note: Refer to Special Instruction, SMHS6998, "Instructions For The Use Of 5P-6518 Fixture Group - Parts Reusability" for complete instructions on the use of the 5P-6518 Dial Indicator Fixture Gp .

  1. Put the dial indicator next to the threaded area on the shaft. Adjust the dial indicator to zero.

  1. Turn the wheel and shaft assembly in the Vee shaped blocks from the side with the wheel.

    Note: The wheel and shaft assembly must not be pushed sideways and the wheel and shaft assembly must not be pushed down while the wheel and shaft assembly is being turned. For best results, use one finger to turn the wheel.

  1. While the wheel and shaft assembly is turned, look at the dial indicator in order to get the TIR. If the TIR is 0.05 mm (0.002 inch) or less, the wheel and shaft assembly can be used again.

Balancing Components

Caterpillar recommends balancing the turbine wheel and the compressor wheel each time the turbocharger is serviced. Because of the large size of the components, balancing will ensure that no problems exist with either component. The amount of time required to balance a component is small, and the benefits of balancing outweigh the loss of time that is required to balance the components.

Some factors that may cause a component to be unbalanced include the following items:

  • Mechanical damage caused by foreign particles

  • Uneven deposits of dirt

  • Erosion of the blade edges on the components caused by the presence of solid particles in the intake air or exhaust gas.

  • There is visible mechanical damage to the turbine shaft and/or compressor wheel

  • When the turbine shaft and/or compressor wheel have been repaired/machined




Illustration 37g02140537

Example of a turbine shaft in a component balancer

In order to purchase a machine for balancing the turbochargers, refer to the following information:

HEINS BALANCING SYSTEMS, INC
820 Railroad Avenue
Santa Paula, California 93060
http://www.heins-balancing.com/services.html
(805) 525-5445Fax (805) 525-7074

Assembly Procedure

Assemble the Cartridge Assembly

Table 8
Part Number     Quantity     Description    
FT-2685     1     Service Stand    
6V-2055     1     Grease    
-         Thread Protector    

Note: Refer to Table 3 and Table 4 for turbocharger component weights.

Table 9
Torque Values for Cartridge Assembly    
    TPS 42     TPS 44     TPS 48     TPS 57     TPS 61    
(1) Compressor Wheel (1)    
55 N·m (41 lb ft)    

95 N·m (70 lb ft)    

160 N·m (118 lb ft)    

290 N·m (214 lb ft)    

490 N·m (361 lb ft)    
(1) Compressor Wheel (2)    
25 N·m (18 lb ft)    

40 N·m (30 lb ft)    

160 N·m (118 lb ft)    

120 N·m (89 lb ft)    

200 N·m (148 lb ft)    
(4) Bolt    
10 N·m (7 lb ft)    

10 N·m (7 lb ft)    

10 N·m (7 lb ft)    

20 N·m (15 lb ft)    

40 N·m (30 lb ft)    
(13) Bolt    
20 N·m (15 lb ft)    

20 N·m (15 lb ft)    

40 N·m (30 lb ft)    

65 N·m (48 lb ft)    

65 N·m (48 lb ft)    
(15) (22) Bolt    
10 N·m (7 lb ft)    

10 N·m (7 lb ft)    

10 N·m (7 lb ft)    

20 N·m (15 lb ft)    

40 N·m (30 lb ft)    
( 1 ) Assembly Torque
( 2 ) Check Loosening Torque



    Illustration 38g02138818



    Illustration 39g03180396



    Illustration 40g02138752

    Exploded View of the Bearing Assembly




    Illustration 41g02139778

    Note: Table 9 should be followed for proper torque values.

  1. Install retaining ring (16) into bearing housing (14). Apply clean engine oil to bearing (17). Install bearing (17). Align the hole in bearing (17) with the hole in bearing housing (14) and install bolt (15). Then, install the other retaining ring (18). Tighten bolt (15) .

    Note: The retaining rings have a rounded edge (A) on one surface and one surface has a rougher edge with a small lip (B). The small lip is caused when the retaining ring was punched out of sheet metal during manufacturing and can be felt with your fingertip. Make sure that the side of the retaining ring with the small lip faces AWAY from the bearing.

  1. Apply clean engine oil to bearing (23) and thrust bearing (20). Install thrust ring (19) and thrust bearing (20). Install auxiliary bearing (21) and bearing housing (24). Install bearing (23). Install bolt (22). Tighten bolt (22) .

    Note: The oil hole in thrust bearing (20) must be aligned with the alignment pin in bearing housing (14) .




    Illustration 42g02138751

    Installing the Turbine Shaft and Bearing Assembly

  1. Install bearing assembly (12) into center housing (11) and install bolts (13). Tighten bolts (13). Apply 6V-2055 Grease to ring (9) and install ring (9) onto the shaft. Make sure that the ends of ring (9) are engaged.

  1. Apply clean engine oil to the turbine shaft (8). Position plate (10) onto center housing (11). Install turbine shaft (8) into center housing (11) and through the bearing assembly (12) .



    Illustration 43g03180618

  1. Install sealing disc (7). Install thread protector (6). Install O-ring seal (3) into bearing plate (3) and install bearing plate (3). Install bolts (4) .



    Illustration 44g02138747

    Installing the Compressor Wheel

  1. Tighten compressor wheel (1) to the proper torque. After torquing the compressor wheel try to loosen it with the "Check Loosening Torque" shown in Table 9. If the wheel loosens then you must disassemble the cartridge group and clean all the axial contact surfaces and repeat the torque procedure. If the wheel does not loosen the re-torque the wheel to the proper assembly torque.

  1. Check the axial clearance and the radial clearance of the bearings. Refer to ""Checking the Clearances of the Bearings" ".

Installing the Cartridge Assembly

Table 10
Torque Values for Installing the Cartridge    
    TPS 42     TPS 44     TPS 48     TPS 57     TPS 61    
(8) Bolt    
35 N·m (26 lb ft)    

35 N·m (26 lb ft)    

70 N·m (52 lb ft)    

105 N·m (77 lb ft)    

105 N·m (77 lb ft)    
(13) Nut    
25 N·m (18 lb ft)    

25 N·m (18 lb ft)    

45 N·m (33 lb ft)    

75 N·m (55 lb ft)    

75 N·m (55 lb ft)    
(14) Sensor    
15 N·m (11 lb ft)    

15 N·m (11 lb ft)    

15 N·m (11 lb ft)    

15 N·m (11 lb ft)    

15 N·m (11 lb ft)    



Illustration 45g02138341

(1) Cartridge Group

(2) Diffuser

(3) Wall Insert

(4) Compressor housing/">Housing

(5) Nozzle Ring

(6) Rupture Ring

(7) Turbine housing/">Housing




    Illustration 46g02138616

  1. Install sealing ring (15) into the turbine housing. Make sure that the sealing ring is layered correctly, as shown. Install nozzle ring (5)



    Illustration 47g02138633

  1. Use the suitable lifting device in order to place the cartridge assembly (1) onto Tooling (B). Install O-ring seal (16) .



    Illustration 48g02139836

  1. Attach a suitable lifting device to the cartridge group (1). Position cartridge group (1) into the turbine housing. Install rings (12) and nuts (13) into the turbine housing. Install sensor (14). Tighten nuts (13) .



    Illustration 49g02139839

  1. Install O-ring seal (10) and O-ring seal (11), if equipped. Install wall insert (3) into compressor housing (4).

  1. Attach a suitable lifting device to the compressor housing (4). Position compressor housing (3) onto the cartridge assembly. Install rings (9) and bolts (8). Tighten bolts (8) .


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