D3C AND D3C LGP TRACTORS / POWERSHIFT / 1PJ00001-UP (MACHINE) POWE...

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Shutdown SIS

Previous Screen

Product: TRACK-TYPE TRACTOR

Model: D3C TRACK-TYPE TRACTOR 1PJ00578
Configuration: D3C AND D3C LGP TRACTORS / POWERSHIFT / 1PJ00001-UP (MACHINE) POWERED BY 3204 ENGINE

Disassembly and Assembly

3204 VEHICULAR ENGINES
Media Number -SENR3230-00 Publication Date -01/10/1985 Date Updated -30/11/2001

Turbocharger
SMCS - 1052-015; 1052-016

Disassemble Turbocharger

START BY:

a. remove turbocharger

1. Put the turbocharger in position on tooling (A).

NOTE: Put alignment marks on the compressor and exhaust housings as to their location on the
cartridge so they can be installed in the same position.

2. Bend the tabs on the locks away from the bolts.

3. Remove bolts (2), locks (1) and compressor housing (3).

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4. Bend the tabs on the locks away from the bolts. Remove bolts (5), the locks and cartridge assembly
(4) from exhaust housing (6).

5. Put the cartridge assembly in position on tooling (B).

NOTICE

Do not put a bending force on the shaft and wheel assembly when the
nut is loosened.

6. Remove nut (7) from the shaft.

NOTICE

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Do not let shaft assembly (9) fall when it is pushed out of the cartridge
assembly.

7. Use a press to push shaft assembly (9) out of the cartridge assembly.

8. Remove wheel (8) from the cartridge.

9. Remove seal ring (11) from shaft assembly (9).

10. Remove shroud (10) from the shaft assembly.

NOTE: Put alignment marks on the cartridge and backplate assembly (14) as to the location of the
backplate on the cartridge so it can be installed in its original position.

11. Bend the tabs on the locks away from the bolts.

12. Remove bolts (13) and locks (12).

13. Remove the cartridge from backplate assembly (14).

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14. Remove bearing (15) and collar (16) as a unit from the backplate assembly.

15. Remove bearing (15) from collar (16).

16. Remove seal ring (17) from collar (16).

17. Remove spring (18) from the backplate assembly.

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18. Remove seal ring (19) from the cartridge housing.

19. Remove snap ring (21), bearing (20) and snap ring (22) from the cartridge housing.

20. Turn the cartridge housing over, and remove snap ring (24), bearing (23) and snap ring (25).

NOTE: For more information on turbochargers, see Analyzing Turbocharger Failures, Form No.
FEG45138, Guideline For Reusable Parts-Turbochargers, Form No. SEBF8018 and Guideline For
Reusable Parts-Specifications For Reusable Turbocharger Components, Form No. SEBF8019.

Assemble Turbocharger

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1. Clean all parts of the turbocharger thoroughly before they are assembled.

2. Install snap ring (2), bearing (3) and snap ring (1) in the cartridge housing. Put clean engine oil on
the bearing.

3. Turn the cartridge housing over, and install snap ring (5), bearing (6) and snap ring (4). Put clean
engine oil on the bearing.

4. Put seal ring (7) in position on the cartridge housing.

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5. Put seal ring (8) in position on collar (9).

NOTICE

Bearing (10) must be installed on the collar with the side that has a
groove up as shown.

6. Put bearing (10) in position on collar (9).

7. Put bearing (10) and the collar in position on the cartridge housing as a unit. Make an alignment of
the holes in the bearing with dowels (11).

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8. Put spring (12) in position in backplate (13).

9. Put shaft assembly (14) in position on tooling (A).

10. Fill the groove in the shaft with 6V2055 High Vacuum Grease.

11. Put seal ring (16) in position on the shaft assembly.

12. Install shroud (15) as shown.

13. Put the cartridge housing in position on shaft assembly (14).

14. Put the backplate in its original position. Install locks (18) and bolts (17). Tighten the bolts to a
torque of 8.5 to 10.2 N·m (75 to 90 lb.in.).

15. Bend the tabs on locks (18) up against the bolts.

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16. Put compressor wheel (19) in position on shaft assembly (14).

17. Use the procedure which follows to install and tighten the nut which holds the compressor wheel
in position.

NOTICE

Do not put a bending force on the shaft and wheel assembly when the
nut is loosened or tightened.

a. Put a small amount of clean engine oil on the threads and impeller face surface that makes contact
with the nut. Install the nut.

b. Tighten the nut to a torque of 2.25 N·m (20 lb.in.) plus 100° more.

c. Remove the nut from the shaft.

d. Put 6V1541 Quick Cure Primer on the threads of the shaft and nut.

e. Put 9S3265 Retaining Compound on the threads of the shaft and nut.

f. Install the nut on the shaft, and tighten the nut to a torque of 2.25 N·m (20 lb.in.) plus 100° more.

18. Put cartridge assembly (20) in a vise as shown. Make sure soft (brass) jaws are used.

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19. Install tooling (C) on the cartridge assembly to check end play. The end play must be 0.03 to 0.10
mm (.001 to .004 in.).

20. Put cartridge assembly (20) in its original position in turbine housing (21).

21. Put 5P3931 Anti-Seize Compound on bolts (23).

22. Put locks (22) in position, and install the bolts. Tighten the bolts to a torque of 13 ± 1.7 N·m (115
± 15 lb.in.). Bend the tabs on the locks against the bolts.

23. Put compressor housing (24) in its original position on the cartridge assembly.

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24. Put locks (25) in position, and install bolts (26). Tighten the bolts to a torque of 13 ± 1.7 N·m (115
± 15 lb.in.). Bend the tabs on the locks against the bolts.

25. Remove the turbocharger from tooling (B).

END BY:

a. install turbocharger

Copyright 1993 - 2019 Caterpillar Inc. Mon Sep 9 01:01:32 UTC+0700 2019
All Rights Reserved.
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