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Producto: ENGINE - MACHINE

Modelo: 3306 ENGINE - MACHINE 64Z
Configuración: 3306 Industrial Engine 64Z05381-UP

Pautas de reutilización y recuperación

Turbochargers{1052}
Número de medio -SEBF8018-04 Fecha de publicación -28/02/2008 Fecha de actualización -29/02/2008

i02826100

Turbochargers{1052}
SMCS - 1052

Electric Power Generation:

SR4 (S/N: 1DJ1-UP)
Engine:
1140 (S/N: 36B1-UP)
1673 (S/N: 74B1-UP; 78B1-UP)
1674 (S/N: 94B1-UP)
1676 (S/N: 54B1-UP)
1693 (S/N: 65B1-UP)
3034 (S/N: 7EF1-UP)
3114 (S/N: 5EF1-UP)
3116 (S/N: 7SF1-UP; 2SG1-UP; 2WG1-UP; 4KG1-UP; 4PG1-UP; 1NJ1-UP; 1SK1-UP; 2BK1-UP)
3116 T (S/N: 9LN1-UP)
3126 (S/N: 8NM1-UP)
3145 (S/N: 96M1-UP)
3150 (S/N: 97M1-UP)
3160 (S/N: 98M1-UP)
3176 (S/N: 2YG1-UP)
3176B (S/N: 9WK1-UP)
3204 (S/N: 2TB1-UP; 3PC1-UP)
3208 (S/N: 29A1-UP; 30A1-UP; 5YF1-UP; 90N1-UP; 40S1-UP; 75V1-UP; 32Y1-UP; 01Z1-UP;
02Z1-UP; 03Z1-UP; 51Z1-UP)
3304 (S/N: 4XB1-UP; 6YB1-UP; 3TC1-UP; 4PC1-UP; 10E1-UP; 13E1-UP; 83Z1-UP)
3304B (S/N: 1YF1-UP; 9HK1-UP; 8XL1-UP; 1PS1-UP)
3306 (S/N: 4WB1-UP; 7HB1-UP; 2ZC1-UP; 5JC1-UP; 64Z1-UP; 84Z1-UP; 85Z1-UP)
3306B (S/N: 7JB1-UP; 5KD1-UP; 3RG1-UP; 2AJ1-UP; 8JJ1-UP; 9SL1-UP; 2TM1-UP; 9NR1-UP;
1RS1-UP; 63Z1-UP)
3406 (S/N: 92U1-UP)
3406B (S/N: 7FB1-UP; 8TC1-UP)
3408B (S/N: 9TD1-UP; 1LG1-UP; 2BG1-UP)
3408C (S/N: 1TS1-UP)
3408E (S/N: 7PR1-UP)
3412 (S/N: 9XF1-UP; 2WJ1-UP; BCS1-UP)
3412C (S/N: BAK1-UP; 9BR1-UP)
3412E (S/N: 4CR1-UP)
3508 (S/N: 6TJ1-UP; 5XM1-UP; 3LS1-UP; 3PS1-UP; 95Y1-UP; 96Y1-UP; 97Y1-UP; 23Z1-UP;
68Z1-UP; 69Z1-UP; 70Z1-UP)
3508B (S/N: S2D1-UP; 1TW1-UP; 2HW1-UP; 3DW1-UP; BPX1-UP)
3512 (S/N: 2WK1-UP; 6PM1-UP; 3MS1-UP; 3RS1-UP; 3WS1-UP; 49Y1-UP; 50Y1-UP; 51Y1-UP;
24Z1-UP; 65Z1-UP; 66Z1-UP; 67Z1-UP)
3512B (S/N: BRC1-UP; 8EM1-UP; 1PW1-UP; 2GW1-UP; 3ZW1-UP)
3512C (S/N: LLB1-UP; LLF1-UP)

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3516 (S/N: 4XF1-UP; 9KF1-UP; 4MJ1-UP; 5SJ1-UP; 7KM1-UP; 3NS1-UP; 3XS1-UP; 27Z1-UP;
28Z1-UP; 29Z1-UP; 71Z1-UP; 72Z1-UP; 73Z1-UP)
3516B (S/N: CBN1-UP; 6HN1-UP; 7RN1-UP; 8CN1-UP; 8KN1-UP; 9AN1-UP; S2P1-UP; S2R1-
UP; 1NW1-UP; 2FW1-UP; 2JW1-UP; 3CW1-UP; 4BW1-UP; S2Z1-UP)
A330A (S/N: 85B1-UP)
D330 (S/N: 82B1-UP; 99B1-UP)
D330A (S/N: 86B1-UP)
D333 (S/N: 80B1-UP; 87B1-UP)
D333A (S/N: 88B1-UP)
D333C (S/N: 09A1-UP)
D334 (S/N: 92B1-UP; 93B1-UP)
D336 (S/N: 55B1-UP; 60B1-UP)
D342C (S/N: 50B1-UP)
D343 (S/N: 33B1-UP; 62B1-UP)
D346 (S/N: 39J1-UP; 40J1-UP; 98N1-UP)
D348 (S/N: 36J1-UP; 38J1-UP; 57K1-UP)
D349 (S/N: 61P1-UP; 62P1-UP; 32R1-UP)
D353E (S/N: 77B1-UP)
D379 (S/N: 76B1-UP)
D379B (S/N: 34Z1-UP)
D398 (S/N: 75B1-UP)
D398B (S/N: 35Z1-UP)
D399 (S/N: 35B1-UP; 91B1-UP; 36Z1-UP)
G3304 (S/N: 37Y1-UP)
G3306 (S/N: 3CF1-UP; 07Y1-UP)
G3406 (S/N: 4FD1-UP; 1RK1-UP)
G3408 (S/N: 6NB1-UP; 6RJ1-UP)
G3408C (S/N: 3WR1-UP; 8YR1-UP; 6FW1-UP)
G3412 (S/N: 7DB1-UP; 3NK1-UP)
G3412C (S/N: 6ZM1-UP; 8LW1-UP)
G342 (S/N: 71B1-UP)
G343 (S/N: 97N1-UP)
G348 (S/N: 92R1-UP)
G349 (S/N: 93R1-UP)
G3508 (S/N: 2JF1-UP; 9TG1-UP; 2TJ1-UP; WPM1-UP; WPN1-UP; DLR1-UP)
G3512 (S/N: 4KC1-UP; 5JD1-UP; 7NJ1-UP; WPP1-UP; WPR1-UP; GNS1-UP; 6JW1-UP)
G3516 (S/N: 3RC1-UP; 8LD1-UP; 4EK1-UP; 5PN1-UP; WPS1-UP; WPT1-UP; WPW1-UP;
8PW1-UP)
G3524 (S/N: 7SZ1-UP)
G3532 (S/N: 8BZ1-UP)
G399 (S/N: 49C1-UP)
:
3306 (S/N: 76R1-UP; 02B1-UP; 04B1-UP; 05B1-UP; 23C1-UP; 66D1-UP; 67D1-UP; 68D1-UP;
70R1-UP; 4TB1-UP; 3ZJ1-UP; 5KJ1-UP; 4CK1-UP; 4JK1-UP; 2WB1-UP; 4RG1-UP; 67U1-UP;
99U1-UP; 28V1-UP; 78Z1-UP; 8RG1-UP; 60M1-UP; 38S1-UP; 81Z1-UP; 25Z1-UP; 31B1-UP;
32B1-UP; 46B1-UP; 47B1-UP; 69B1-UP; 66B1-UP; 67B1-UP)
Generator Set:
3406 GEN SET (S/N: 4ZR1-UP; 75Z1-UP)
3406B GEN SET (S/N: 4PM1-UP)
3406C GEN SET (S/N: 1LS1-UP; 8FS1-UP)
3412C GEN SET (S/N: BAX1-UP)
Industrial Engine:
3054C (S/N: 3341-UP)
3406 IND (S/N: 90U1-UP)
3406B IND (S/N: 6TB1-UP)
3412E IND (S/N: BDT1-UP)
D342C IND (S/N: 05A1-UP; 49B1-UP)
Marine Engine:
3406 MARINE (S/N: 91U1-UP)
3406C MARINE (S/N: 1SS1-UP)

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3408C MARINE (S/N: 9ER1-UP)

3412E MARINE (S/N: 9PW1-UP)
Track-Type Tractor:
4S (S/N: 02A1-UP)

Introduction
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 additional information about this guideline, consult Repair Process Engineering of the Marketing &
Product Support Division at 1 (309) 675-5434.

Summary
This guideline can be used in the selection of turbocharger parts to be used again during the reconditioning
operation. A visual comparison can be made between the turbocharger components removed during
disassembly and the illustrations in this guideline in order to find out if turbocharger components can be used
again. Many times, the use of new turbocharger components is not necessary. Installation of used turbocharger
components during turbocharger reconditioning will give acceptable service life and a large reduction in the
cost of a rebuilt turbocharger. During the reconditioning of the turbocharger, correct any conditions that caused
the original failure before the turbocharger is put back into operation.

Note: Use 6V-2055 Grease in the seal ring grooves during all turbocharger reconditioning.

References
ReferenceReuse and Salvage Guideline, SEBF8019, "Specifications for Reuseable Turbocharger
Components"

ReferenceSpecial Instruction, SMHS6998, "Instructions For The Use Of 5P6518 Fixture Group - Parts
Reusability"

ReferenceCatalog, NENG2500, "Dealer Service Tools Catalog"

Service Level of the Turbocharger

The service level of the turbocharger determines the components of the turbocharger that should be
disassembled. The service level of the turbocharger determines the reusability of the individual parts. The
service level of a turbocharger determines the components that should be disassembled. If the assembly of the
turbocharger cartridge is the lowest level of service that is available then the cartridge assembly should not be
disassembled. This guideline does not list specifications for reusability for parts that are nonserviceable.

Required Tooling
Table 1

Part Number Description

266-3452 Emery Polishing Paper
6V-2055 Grease

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5P-2170 Dial Bore Gauge Group

4M-6646 Grooved Pin
7447 3M Type A Scotch-Brite Very Fine General Purpose Pad.
5P-6518 Dial Indicator Fixture Gp
763 N/F Magnus Heavy-Duty Carbon Solvent

Specifications
Some parts will need to be measured in order to know if the parts can be used again. The methods of
measurement will be given in respective sections in this guideline.

Note: Refer to Reuse and Salvage Guideline, SEBF8019, "Specifications for Reuseable Turbocharger
Components" for specifications of wear.

Cleaning Procedures
General

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

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Illustration 1 g01410053
Masking tape is used on the shaft and the bearing journals for protection from glass beads.

Illustration 2 g01410109
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 can not 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.

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Compressor Wheels

Illustration 3 g01410114
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

Illustration 4 g01410119

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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.

Illustration 5 g01410120
Remove carbon deposits from the draining cavity with a carbon scraper. The carbon scraper can be made from 1.5 mm (0.06 inch)
thick mild steel.

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

Illustration 6 g01410121
Dimensions for making a carbon scraper from 1.5 mm (0.06 inch) thick mild steel

(A) 9.7 mm (0.38 inch)

(B) 19.1 mm (0.75 inch)

(C) 38.1 mm (1.50 inch)

(D) 3.8 mm (0.15 inch)

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(E) 228.6 mm (9.00 inch)

(F) 2.29 mm (0.090 inch)

(G) 38.1 mm (1.50 inch)

Compressor and Turbine Housings

After cleaning, use air under pressure to remove foreign material from the inside of the housings.

Inspection Procedures
Turbine Wheel and Shaft Assembly

Nomenclature

Illustration 7 g01410122
(1) Blade

(2) Oil ring groove

(3) Threaded area

(4) Bearing journals

(5) Hub area

Blades

Turbine wheel and shaft assemblies with cracks in the blades or broken blades cannot be used again.

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Turbine wheel and shaft assemblies can be used again if the blades are slightly bent. Turbine wheel and shaft
assemblies with severely bent blades cannot be used again. Make sure that the bent blades do not have any
cracks.

Use the Zyglofluorescent penetrant process in order to inspect the assembly of the turbine wheel and shaft for
cracks. For information on Zyglo, contact the following company.

Magnaflux Corporation
3624 W. Lake Ave.
Glenview, Il 60026
http://www.magnaflux.com/country.htm
Telephone: 800-421-1569

Note: Do not straighten bent blades.

Illustration 8 g01410123
Turbine wheel has cracks in one blade and one broken blade.

Do not use the part again.

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Illustration 9 g01410126
The turbine wheel has one slightly bent blade and no cracks.

Use the part again.

Illustration 10 g01410131
Turbine wheel has severely bent blades.

Do not use the part again.

Illustration 11 g01410132
The turbine wheel has a large amount of damage from foreign material.

Do not use the part again.

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Illustration 12 g01410133
The turbine wheel has a small nick. The turbine wheel can be used again after the burrs are removed. Use a small file or an emery
cloth that is medium grit to remove the burrs.

Use the part again.

Illustration 13 g01410134
Turbine blades show light damage from rubbing 360° around the turbine wheel.

Use the part again.

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Illustration 14 g01410135
Turbine blades show light damage from rubbing 360° around the turbine wheel.

Use the part again.

Illustration 15 g01410136
Turbine blades show heavy rubbing.

Do not use the part again.

Back Face of Turbine Wheel

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Illustration 16 g01410138
Turbine wheel shows heavy rubbing on the back face.

Do not use the part again.

Oil Seal Ring Grooves

The carbon deposits must be removed before the grooves are checked. Refer to ""Cleaning Procedures" " for
removal of the carbon deposits.

Use the procedure that follows to find the width of the seal ring grooves.

1. Use a micrometer to measure the width of a new oil seal ring. Record this dimension.

2. Install the oil seal ring in the groove of the oil seal. Measure the clearance between the seal ring and the
sidewall of the groove with a feeler gauge.

3. Add this dimension to the dimension for the width of the seal ring. This dimension will be the width of
the seal ring groove.

If the width of the seal ring groove is more than the dimension given under the maximum width of the seal ring
groove in the Reuse and Salvage Guideline, SEBF8019, "Specifications for Reusable Turbocharger
Components", then the turbine wheel and shaft assembly cannot be used again.

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Illustration 17 g01410139
The seal ring groove has a wear step in the outboard groove.

Do not use the part again.

Some wheel and shaft assemblies have two seal ring grooves. The wheel and shaft assemblies that have two
seal ring grooves can be used again if the wear of the outboard groove next to turbine wheel is within the
specifications of wear. The wheel and shaft assemblies with two seal ring grooves can be used again if the
inboard groove contains wear. Use both oil seal rings on these wheel and shaft assemblies.

If the wear of the outboard groove is not within the specifications of wear then the wheel and shaft assembly
cannot be used again.

Note: At all times, use 6V-2055 Grease in the seal ring grooves before the seal rings are installed. This grease
helps the seal rings in order to prevent leakage when the turbocharger is first put into operation.

Illustration 18 g01410140

The inboard groove has wear. The outboard groove width is within the specifications of wear.

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(6) Outboard groove

(7) Turbine wheel

Use the part again.

Illustration 19 g01410142
There is too much wear in both of the seal ring grooves.

(6) Outboard groove

(7) Turbine wheel

Do not use the part again.

Illustration 20 g01410144
Wheel and shaft assembly has damage to the seal ring groove. If the wheel and shaft assembly has two seal ring grooves then both
grooves must be free of damage in order to be used again.

Do not use the part again.

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Illustration 21 g01410145
Wheel and shaft assembly shows erosion in the hub area of the shaft.

Use the part again.

Bearing Journals

Illustration 22 g01410146
The bearing journal has deep scratches and excessive wear.

Do not use the part again.

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Illustration 23 g01410147
The bearing journal has metal deposits from the bearing.

Do not use the part again.

Wheel and shaft assemblies that show light scratches or shiny areas on the bearing journals can be used again
after the journals are polished and if the wheel and shaft assemblies are within the specifications of wear.
Polish the bearing journals with 266-3452 Emery Polishing Paper .

After the bearing journals are polished, measure each journal diameter with a micrometer. If the dimension that
is measured is less than the dimension that is given under the minimum diameter of the bearing journal in the
Reuse and Salvage Guideline, SEBF8019, "Specifications for Reusable Turbocharger Components", then the
turbine wheel and the shaft assembly can not be used again.

Note: Some bearing journals in turbochargers that have been remanufactured may be smaller than the standard
size of bearing journals. Replacement bearings for these journals must be the correct size.

Illustration 24 g01410149
The bearing journal has light scratches. The bearing journal can be used again if the diameter is within specifications and the
bearing journal is polished with 266-3452 Emery Polishing Paper .

Use the partagain after polishing.

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Illustration 25 g01410151
The bearing journal in Illustration 24 after the bearing journal was polished.

Illustration 26 g01410152
The bearing journal has a single deep scratch. The bearing journal can be used again if the diameter is within specifications and the
bearing journal is polished.

Use the part again after polishing.

Shaft Areas

Wheel and shaft assemblies that show discoloration, carbon deposits and/or deposits of lacquer can be used
again after the wheel and shaft assemblies are cleaned. Refer to ""Cleaning Procedures" " in this document.

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Illustration 27 g01410153
The shaft shows discoloration and the shaft can be used again after the shaft is cleaned.

Use the partagain after cleaning.

Before the wheel and shaft assembly is assembled in the turbocharger, the bearing journals must be polished
with 266-3452 Emery Polishing Paper . The bearing journals must be then measured with a micrometer and
checked to Reuse and Salvage Guideline, SEBF8019, "Specifications for Reuseable Turbocharger
Components". Finally, the bearing journals must be cleaned in a good solvent.

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Illustration 28 g01410155
The shaft was cleaned in order to remove discoloration, carbon deposits and/or deposits of lacquer.

Use the part again.

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Illustration 29 g01410156
The shaft shows damage from a compressor wheel that has turned on the shaft.

Do not use the part again.

Illustration 30 g01410158
The shaft has damage of the threads. The shaft can be made usable by the use of the correct rethreading die.

Use the part again.

Note: Do not use wheel and shaft assemblies with severely damaged threads. Wheel and shaft assemblies that
have threads which have been pulled or stretched must not be used again.

Bend of the Shaft

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Illustration 31 g01410159
The shaft is bent more than the Total Indicator Reading (TIR) but the shaft can be used again after the shaft is made straight. The
TIR is 0.05 mm (0.002 inch). The scale is used for illustration purposes only. Do not use a scale or a straight edge to check for a
bent shaft.

Use the part again after the shaft is straightened.

Illustration 32 g01410160
Use 5P-6518 Dial Indicator Fixture Gp to check for bent shafts.

Process of Measuring

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

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 .

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

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3. 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.

4. 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.

Procedure to Straighten

If the TIR is more than 0.05 mm (0.002 inch) put a mark with a pencil on the shaft at the highest indicator
reading and use the procedure that follows to straighten the shaft.

1. Remove the wheel and shaft assembly from the 5P-6518 Dial Indicator Fixture Gp . Make sure that the
mark on the shaft is visible.

NOTICE
Do not put the threaded end of the shaft on a metal table or other hard
surfaces when the shaft is hit. These surfaces will damage the threads
on the shaft.

Illustration 33 g01410161
Hit the shaft lightly with a plastic or a lead hammer. The shaft must be on a piece of wood.

2. Put the wheel and shaft assembly on a piece of softwood. Turn the shaft until the mark is up. Lightly hit
the shaft in the lower area of the bearing journal with a plastic or a lead hammer.

3. Put the wheel and shaft assembly in the 5P-6518 Dial Indicator Fixture Gp and check the TIR again. If
the TIR is more than 0.05 mm (0.002 inch) the shaft must be straightened until the TIR is correct.

Compressor Wheel

Nomenclature

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Illustration 34 g01410163
(1) Blade

(8) Nut Face

(9) Bore

Blades

Compressor wheels that have cracked blades, severely bent blades, or broken blades can not be used again.

Compressor wheels can be reused if the blades have a slight amount of bend. Make sure that cracks are not
present in the bent blades. TheZyglo procedure can be used to check for cracks if the procedure is available. If
cracks are present then the compressor wheel cannot be used again.

Illustration 35 g01410164
Compressor wheel had a broken blade.

Do not use the part again.

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Note: Do not straighten bent blades.

Illustration 36 g01410165
The compressor wheel has one slightly bent blade. The compressor wheel does not have any cracks.

Use the part again.

Illustration 37 g01410168
Compressor wheel has severely bent blades.

Do not use the part again.

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Illustration 38 g01410169
The compressor wheel has a small nick in the blade. The compressor wheel can be used again after the burrs are removed. Use a
small file and 266-3452 Emery Polishing Paper to remove the burrs.

Use the part again.

Illustration 39 g01410187
Compressor wheel shows a large amount of damage from foreign material.

Do not use the part again.

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Illustration 40 g01410189
Compressor wheel blades show a minor amount of rubbing 360 degrees around the compressor wheel.

Use the part again.

Illustration 41 g01410190
Compressor wheel blades show a minor amount of rubbing 360 degrees around the compressor wheel.

Use the part again.

Compressor wheels that have light rubbing on the blades less than 360 degrees around the compressor wheel
cannot be used again. If there are small burrs on the blades in the area of the light rubbing, then the burrs must
be removed with a small file or an emery cloth that is medium grit.

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Illustration 42 g01410191
Compressor wheel blades show heavy rubbing.

Do not use the part again.

Nut Face

A compressor wheel nut that has been tightened too much can cause damage to the face. If compressor wheels
with damaged nut faces are used again, a failure to the turbocharger is possible.

Illustration 43 g01410192
Compressor wheel has damage on the nut face.

Back Face

Compressor wheels that have rubbing on back faces cannot be used again.

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Illustration 44 g01410194
Compressor wheel shows rubbing on the back face.

Do not use the part again.

Bore

Illustration 45 g01410195
The bore of the compressor wheel has grooves. (The compressor wheel was cut in half for illustration purposes.)

Do not use the part again.

Compressor wheels that have minor amounts of axial scratches in the bore can be used again if the scratches
are visible but not able to be felt with a small piece of wire. Compressor wheels that have deep grooves or
other damage in the bore cannot be used again.

Note: Some compressor wheels have a hole for balance in the bore of the compressor wheel.

Compressor Housing

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Nomenclature

Illustration 46 g01410197
(10) Bore of the outlet

(11) Bore of the inlet and contour

(12) Vanes

Contour Bore and Vanes

Illustration 47 g01410198
The compressor housing shows damage to the vanes from foreign material.

Do not use the part again.

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Illustration 48 g01410200
The compressor housing has light pitting in the bore.

Use the part again.

Illustration 49 g01410201
The compressor housing shows damage from foreign material.

Do not use the part again.

Compressor housings that have minor amounts of rubbing or scratches in the area of the contour of the bore
can be used again.

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Illustration 50 g01410202
Compressor housings show light rubbing in the area of the contour of the bore.

Illustration 51 g01410203
Compressor housings show light rubbing in the area of the contour of the bore.

Use the part again.

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Illustration 52 g01410204
The compressor housing has deep grooves in the area of the contour of the bore.

Do not use the part again.

Note: Machine T1810 compressor housings during reconditioning. Machining the compressor housings will
prevent possible future damage of the bore.

Illustration 53 g01410205
The dimensions are for the machining of a larger bore of the inlet on the compressor housing of T1810 turbochargers.

(H) Align the bore to this face within 0.05 mm (0.002 inch).

(J) 230.2 mm (9.0630 inch) diameter

(K) 75.66 ± 0.05 mm (2.979 ± 0.002 inch) concentric within ± 0.05 mm (± 0.002 inch) TIR with 230.2 mm (9.0630 inch) diameter

(L) This area must be reworked by hand in order to remove the sharp change in shape from the straight bore. The area should have a
minimal change in shape.

Note: The area (L) must be reworked by hand in order to remove the sharp change in shape from the straight
bore. The area should have a minimal change in shape.

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Illustration 54 g01410207
The compressor housing shows a deposit of material from the compressor wheel on the contour of the bore. The compressor
housing can be used again after the deposit is removed with emery cloth that is 80 abrasive grit. Clean the housing thoroughly with
solvent.

Use the part again.

Note: Remove the deposit of material only. Do not change the shape of the contour of the bore.

Bores for the O-Rings

Compressor housings with wear in the bores for the O-rings of the inlet and/or outlet can be used again if there
is good contact between the O-ring seals and the bore.

Turbine Housing

Nomenclature

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Illustration 55 g01410208
(13) Inlet flange

(14) Contour of the bore

Illustration 56 g01410210
The turbine housing has a crack on the outside.

Do not use the part again.

Illustration 57 g01410212

The turbine housing has cracks only in the area of the seal flange. If the only cracks that are present are similar to crack (16) then
the housing can be used again. If the cracks are extended past the area of the seal flange, similar to cracks (15) then the housing can
not be used again.

(15) Cracks that extend past the seal flange

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(16) Crack

Bolt Holes

Illustration 58 g01410688
The exhaust housing has broken bolts and the exhaust housing can be used again after the broken bolts are removed. The threads in
the bolt holes must be checked for damage. Repair the threads of the bolt holes if the threads need to be repaired.

Use the part again.

Contour of the Bore

Illustration 59 g01410214
The turbine housing has minor amounts of erosion on the contour of the bore.

Use the part again.

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Illustration 60 g01410215
The turbine housing has heavy erosion on the contour of the bore.

Do not use the part again.

Turbine housings that have light rubbing or scratches on the area of the contour of the bore can be used again.
Turbine housings that have heavy rubbing or deep grooves on the area of the contour of the bore cannot be
used again.

Illustration 61 g01410216
The turbine housing shows a deposit of material of the turbine wheel on the contour of the bore. The housing can be used again after
the deposit is removed with a grinding wheel.

Use the part again.

Note: Remove the deposit of material only. Do not change the shape of the contour of the bore.

Inlet Flange

Some inlet flanges have a web that divides the inlet opening in half. Exhaust housings with erosion on this web
cannot be used again.

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The inlet flange must be checked for flatness. A straight edge and a feeler gauge should be used in order to
measure the width and the length of the inlet flange. If the amount of warp is more than 0.25 mm (0.010 inch),
then the inlet flange can be machined in order to get the flange within specifications. A maximum of 0.25 mm
(0.010 inch) material can be machined from the inlet flange.

Note: A gasket with a dividing web must be used if the turbine housing has a dividing web and the exhaust
manifold has a dividing web. If either of the two does not have a dividing web, use a gasket without a dividing
web.

Illustration 62 g01410217
The turbine housing shows erosion on the web and cracks in the inlet flange. The cracks go into the area of the gasket.

Do not use the part again.

Bore for Outlet

Turbine housings with wear in the bore of the outlet can be used again if there is good contact between the seal
rings and the bore.

Center Housings

Nomenclature

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Illustration 63 g01410218
(17) Bore

(18) Oil hole

Illustration 64 g01410219
The center housing was cut in half for illustration purposes.

(19) Bore for the oil seal ring

(20) Cavity for oil supply

(21) Back cavity of the oil drain

(22) Snap ring grooves

(23) Bearing bores

Snap Ring Grooves

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Illustration 65 g01410220
The center housing has a damaged snap ring groove.

Do not use the part again.

Bore for the Oil Seal Ring

Center housings that have deep grooves or excessive damage to the seal ring bore cannot be used again.

A center housing with a bore for the seal ring that has a minor amount of scratches can be used again after the
seal ring bore is cleaned and measured. Use 266-3452 Emery Polishing Paper to clean the seal ring bore.

Measure the bore with the 5P-2170 Dial Bore Gauge Group and the correct master ring. Center housings with
a bore for the seal ring that is larger than the dimension in the Reuse and Salvage Guideline, SEBF8019,
"Specifications for Reusable Turbocharger Components" can not be used again.

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Illustration 66 g01410221
The center housing has a bore for the seal ring with excessive damage.

Do not use the part again.

Bearing Bore

Center housings can not be used again if center housings have deep scratches or grooves around the bearing
bores. If a few deep scratches or grooves come out of the cavity for oil supply then the center housing can be
used again.

Illustration 67 g01410223
The bearing bore in the center housing shows deep scratches and grooves.

Do not use the part again.

Illustration 68 g01410224
A small number of deep scratches come from the cavity for oil supply.

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Use the part again.

Illustration 69 g01410225
The bearing bore in the center housing has light scratches and shiny areas. The housing can be used again after the housing is
cleaned and if the bearing bore diameter is within specifications.

Use the part again.

Illustration 70 g01410226
The bearing bore in the center housing shows discoloration. The bearing bore can be used again after the housing is cleaned and if
the bearing bore diameter is within specifications.

Use the part again.

Polish the bearing bores with 266-3452 Emery Polishing Paper . Measure the inside diameter of the bores with
the 5P-2170 Dial Bore Gauge Group . The bores on turbocharger models T04 and T04B must be measured
with a telescoping gauge and a micrometer. Center housings with bearing bores that are larger than the
dimensions in the Reuse and Salvage Guideline, SEBF8019, "Specifications for Reusable Turbocharger
Components" can not be used again.

Note: In some turbochargers that have been remanufactured, the diameter of the bearing bore may be larger

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than the standard size. Replacement bearings for these bores must be the correct size.

Area of the Flange

Center housings that show light erosion can be used again. Center housings that show heavy erosion cannot be
used again.

Clamp plates hold the center housing to the exhaust housing on T 1200 series of turbochargers. If these clamp
plates show excessive wear, then the clamp plates cannot be used again. The clamp plates can also cause wear
to the mounting flange of the center housing. The thickness of the flange must be measured in order to find out
if a center housing with wear on the mounting flange can be used again. Measure the thickness of the flange at
a point approximately 1.57 mm (0.062 inch) inside the outside diameter of the flange. The measurement must
be 4.11 mm (0.162 inch) to 4.24 mm (0.167 inch) in order to use the housing again.

Illustration 71 g01410227
The center housing shows light erosion.

Use the part again.

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Illustration 72 g01410228
The center housing shows heavy erosion.

Do not use the part again.

Retaining Pins for the Thrust Washer

Some turbocharger center housings have retaining pins that are hollow. Center housings with hollow pins that
are damaged can be made usable by the installation of new solid pins.

Center housings that have damaged pins or broken pins cannot be used again.

Illustration 73 g01410229
The center housing has damaged retaining pins of the thrust washer.

Do not use the part again.

Installation of New Retaining Pins

1. Remove the damaged pins or the broken pins with a sharp chisel and a hammer. Be careful not to
damage the contact surface of the thrust washer. If the surface is damaged, the thrust bearing will not lie
flat.

2. Grind any remaining part of the pins so the pins are even with the surface of the center housing. There
must not be any of the pin above the surface of the center housing.

3. Put the turbine wheel and shaft assembly in position on the correct service tool of the turbine holder.
Install the turbine and end bearing on the shaft assembly. If necessary, refer to the Catalog, NENG2500,
"Dealer Service Tools Catalog" for the correct turbine holder.

4. Install the center housing with the damaged pins on the shaft assembly.

5. Install the compressor end bearing on the shaft assembly.

6. Put a new thrust washer in position on the center housing so the holes in the washer are in alignment
with the old pins. The thrust washer must be turned 15 degrees in the counterclockwise direction. Make
sure that the center of the thrust washer is the same distance from the shaft at all points.

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Note: Grease can be applied on the bottom of the thrust washer in order to keep the thrust washer in the
center position. Be sure to remove the grease with solvent before the turbocharger is assembled.

7. Use a punch in order to make a mark for the location of the installation of the new pins on the center
housing.

8. Drill the two holes for the new pins. The two holes should have a 2.405 ± 0.023 mm (0.0947 ± 0.0009
inch) diameter. The depth of the two holes should be 5.00 ± 0.20 mm (0.1969 ± 0.0079 inch). Drill a
3.40 ± 0.51 mm (0.1339 ± 0.0201 inch) diameter by a 45 degrees counterbore.

9. Install new 4M-6646 Grooved Pins . The grooved end of the pin should be installed in the center
housing. The pins must not be above the thrust washer after the washer is installed on the pins.

Miscellaneous Parts

Thrust Collar or Ring

Illustration 74 g01410230
The thrust collar has deep scratches and grooves. Do not machine the thrust collar in order to remove wear.

Do not use the part again.

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Illustration 75 g01410231
The thrust collar has light scratches and the thrust collar can be used again after the thrust collar is cleaned with 266-3452 Emery
Polishing Paper . Put the paper on glass or a surface plate and add oil. Then, turn the thrust collar on the paper. Wash the thrust
collar in a clean solvent and put the oil on the thrust collar in order to prevent rust.

Use the part again.

Illustration 76 g01410232
The thrust collar has shiny areas and the thrust collar can be used again after the thrust collar is cleaned with 266-3452 Emery
Polishing Paper .

Use the part again.

The thrust rings will show the same type of wear as the thrust collars. if a face of a thrust ring becomes worn
the ring can be turned over so the opposite face will get the wear.

Note: Thrust collars that are turned over can not be used again. The end play of the assembly of the turbine
wheel and shaft must be checked after a thrust collar or a thrust ring is installed. Check the correct Service
Manual for the end play of the shaft assembly.

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Illustration 77 g01410233
The thrust ring has deep scratches and grooves. The thrust ring can be used again after the thrust ring is turned over.

Use the part again.

Wheel Shroud

Illustration 78 g01410234
The wheel shroud has a crack.

Do not use the part again.

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Illustration 79 g01410235
The wheel shroud shows excessive erosion.

Do not use the part again.

Illustration 80 g01410236
The wheel shroud shows damage from contact of the shaft.

Do not use the part again.

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Illustration 81 g01410237
The wheel shroud has discoloration and the wheel shroud can be used again after the wheel shroud is cleaned.

Use the part again.

Wheel shrouds that show discoloration can be used again after wheel shrouds are cleaned.

Illustration 82 g01410238
The wheel shroud has discoloration. Half of the shroud has been cleaned with glass beads.

Use the part again.

Finger Sleeves and Thrust Spacers

Most turbochargers use either a flinger sleeve or a thrust spacer at the compressor end of the shaft assembly.

The seal ring grooves in these parts must be checked for excessive wear. If there is excessive wear in the seal
ring grooves, the parts can not be used again. Use the procedure that follows to measure the width of the seal
ring grooves.

1. Make sure that the seal ring grooves are clean and free of carbon.

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2. Measure the width of a new seal ring. Record this dimension.

Note: Some of these parts use two seal rings in the same groove. A measurement of both seal rings is
necessary.

3. The seal rings are then installed into the seal ring groove that will be measured. Measure the clearance
between the seal ring and the side wall of the groove with a feeler gauge.

4. Add this dimension to the dimension for the width of the seal ring or rings. This dimension will be the
width of the seal ring groove.

If the width of the seal ring groove is more than the dimension that is given in Reuse and Salvage Guideline,
SEBF8019, "Specifications for Reusable Turbocharger Components", then the flinger sleeve or the thrust
spacer can not be used again.

Illustration 83 g01410239
The flinger sleeve shows no wear and the seal ring groove is within specifications.

Use the part again.

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Illustration 84 g01410240
The thrust spacer shows no wear and the seal ring grooves are within specifications.

Use the part again.

Insert For The Compressor End

Some turbochargers have an insert at the compressor end of the shaft assembly.

Illustration 85 g01410242
The insert shows wear in the area of the bore.

Do not use the part again.

Illustration 86 g01410243
The insert shows no wear in the area of the bore.

Use the part again.

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Thrust Plates

Illustration 87 g01410244
The thrust plate has discoloration, light scratches and shiny areas on the washer. The thrust plate also shows shiny areas in the bore.

Use the part again.

Illustration 88 g01410247
The thrust plate shows deep scratches and grooves in the washer.

Do not use the part again.

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Illustration 89 g01410245
The thrust plate shows excessive wear in the bore. The thrust plate also shows cracks in the bore.

Do not use the part again.

Illustration 90 g01410248
The washer on the thrust plates has turned. The washer is over part of the pins that hold the washer.

Do not use the part again.

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Illustration 91 g01410249
Use a can of oil to check the oil holes. The oil holes must be clean and free of erosion.

Note: The washer of the thrust plate is held by pins. Make sure that the washer is tight. Hold the washer by the
center flange and try to move the washer. If the washer can be moved by this method, the thrust plate can not
be used again. If the thrust plate can be used, clean the thrust plate in a heavy-duty carbon solvent, and put
lightweight oil on the thrust plate in order to prevent rust.

Thrust Bearings

The thrust bearings have a lead tin overlay and this overlay will be removed during the operation of the
turbocharger. If the thrust bearings have light wear or small amounts of lead tin overlay that has been removed
then the bearing can be used again. Thrust bearings that show deep scratches, grooves or excessive wear on
either face can not be used again.

Illustration 92 g01410250
Thrust bearing shows light wear.

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Illustration 93 g01410251
Thrust bearing shows light wear.

Use the part again.

Illustration 94 g01410252
Thrust bearing shows light wear.

Use the part again.

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Illustration 95 g01410253
Thrust bearing has deep scratches and grooves. Check the oil hole with a wire. Oil hole must be open and free of foreign material.

Illustration 96 g01410255
Check the oil hole with a wire. Oil hole must be open and free of foreign material.

Do not use the part again.

If the thrust bearing can be used again, then clean the thrust bearing in a heavy-duty carbon solvent before the
thrust bearing is installed in the turbocharger.

Storage Procedures
Proper protection of the part from corrosion is very important. Corrosion will start in as little as one hour after
the part has been cleaned.

When the part will not be inspected for one hour or less the part should be coated with a rust or corrosion
inhibitor or coated with clean engine oil. The part should be individually wrapped in order to prevent
contamination, and the part should be stored in a protected area in order to avoid damage. See Illustration 97.

When the part will not be inspected in two days or more, the part should be coated with a rust or corrosion

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inhibitor or coated with clean engine oil and the part should be individually wrapped. The wrapped part should
be placed in a container which is clean and structurally solid. The container should be covered or wrapped in
plastic in order to prevent damage and contamination to the part. See Illustration 98.

See Table 2 for recommended rust inhibitors.

Illustration 97 g01245635
Example of protection for a component that is stored for a shorter term

Illustration 98 g01245640
Example of protection for a component that is stored for a longer term

Table 2

Recommendations for Storage

Part Number
Quantity Description Storage Protection

Hard film
Up to one year storage
222-3121 355 mL (12 oz) Rust Preventive
Aerosol Outside conditions for
storage

1U-8809 One year storage

3.79 L (1 US gal)
Caterpillar 450Rust Preventive Oil
Covered conditions for
1U-6523 208 L (55 US gal)
storage

Wax film
1U-8801
3.79 L (1 US gal) Caterpillar 4ARust Preventive Oil Up to one year storage

Outside conditions for

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208 L (55 US gal) storage

1U-6526

Copyright 1993 - 2008 Caterpillar Inc. Wed Jun 18 12:21:25 EST 2008
Todos los derechos reservados.
Red privada para licenciados del SIS.

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