CARTRIDGE GP-TURBOCHARGER 3866321 - Caterpillar

Illustration 8 g02392756
Bolt hole salvage.Note: If using this method of repair, use a maximum of two to three washers per hole [not to exceed 3.05 mm (0.120 inch) thickness]. Make sure that the face height of washer is flush with the flange surface. When more than five bolt holes are damaged, metal spray back to original diameter.Salvage of Pin Bore
Make positioning blocks, Illustration 9, to hold the carrier in relationship to the absolute zero point of the fixture. Use leveling jacks and clamps to hold carrier in place.
Illustration 9 g02392896
Locating blocks to position carrier.
Illustration 10 g02392956
Locate carrier with pin bores aligned in vertical and horizontal directions. Secure carrier to holding fixture. Reference Illustration 11.
Illustration 11 g02392978
Check centerline of all four bores. Make sure the line of true position to each other does not exceed 0.01 mm (0.0004 inch). (P) Outside diameter of carrier 1054.00 0.08 mm (41.496 0.003 inch). (Q) Radius from centerline 287.58 mm (11.322inch). (R) Distance between opposite bores 575.12 mm (22.642 inch). (X) Distance between adjacent bores 406.69 mm (16.011 inch).
Correctly locate the carrier onto the fixture for machining. Establish the X and Y axes in relation to the four pin bores (see Illustrations 10 and 11).
Install a dial indicator into spindle of vertical mill and zero (center) the pin bore.
Place spindle directly in line with one pin bore.
Position dial indicator into pin bore hole and zero (center) hole to within 0.03 mm (0.001 inch) total indicator reading (TIR).
Illustration 12 g02393202
Zero (center) the pin bore to be salvaged within 0.03 mm (0.001 inch) TIR.
After the pin bore is centered, lock the vertical and horizontal axes to prevent table movement.
Remove the dial indicator and place the boring bar into the spindle.
Illustration 13 g02393256
Rough machine the pin bore to 105.33 mm (4.147 inch). Then, finish machine to 106.60 0.013 mm (4.197 0.0005 inch).
Make insert adjustments and counter bore inside face of bore to accept shoulder of sleeve.Note: Sleeves are pressed into place from rear of bore, forming a new surface inside the bore. Finish machine the sleeves inside diameter after installation into the carrier to 101.676 0.013 mm (4.003 0.0005 inch).Note: Finish machine on both faces of insert flush with carrier.
Prior to installation, the sleeve must be cleaned with 6V-1541 Quick Cure Primer and inspected thoroughly.
Coat sleeves with 9S-3263 Thread Lock to promote thermal conduction of heat inside the bore and to prevent rotation of the sleeve. Install sleeves.
Sleeve should be flush with back face of carrier as shown in Illustration 14. If not, a backfacing operation to the sleeve is necessary.
Illustration 14 g02393318
Machining dimensions. (A) Thrust face diameter 135.00 mm (5.315 inch) (B) Thrust face diameter 140.00 mm (5.512 inch) (S) 9.00 mm (0.354 inch) (T) 60 0.41 mm (2.36 0.016 inch) radius (U) 138.02 mm (5.434 inch) (V) 112.00 mm (4.409 inch) (W) 101.68 0.013 mm (4.003 0.0005 inch)
Illustration 15 g02393456
Backface sleeve until flush with carrier.
Repeat Steps 2 through 7 on remaining damaged bores.
Illustration 16 g02393461
Carrier has been repaired with sleeve insert.