Thi! $-2990-201-45 DEPARTMENT OF THE ARMY TECHNICAL MANUAL General Support and Depot Maintenance Manual (Including Repair Parts and Special Tools List) for TURBOCHARGER, ENGINE ASSEMBLY 2990-074-8930 (SCHWITZER MODEL 4-456) 2990.974.7583 (SCHWITZER MODEL 40-554) 2990-967-9909 (SCHWITZER MODEL 4D-454C) 2990-999-2275 (SCHWITZER MODEL ALE-354) AND 2950-178-1245 (SCHWITZER MODEL 4LE-456) This copy is a reprint which includes current pages from Changes 1 and 2 HEADQUARTERS, DEPARTMENT OF THE ARMY SEPTEMBER 1964rm 9.2090-201-45, ‘TECHNICAL MANUAL, HEADQUARTERS DEPARTMENT OF THE ARMY No, 9-20900-201-45, ‘Washington, D. C., 20025, S0September 1964 ‘TURBOCHARGER, ENGINE, ASSEMBLY _2900-860.2382 (SCHWITZER MODEL 4-450) 2490-074.8980 (SCHWITZER MODEL 4 Paragraph Page CHAPTER 1 INTRODUCTION Section 1 General =~ 1 1 Th —Deseription and ra i CHAPTER 2 PARTS, SPECIAL TOOLS, AND EQUIPMENT For. (GENERAL SUPPORT AND DEPOT MAINTENANCE. o9 ‘ CHAPTERS TROUBLESHOOTING ° Section 1 General wong 1 Troubleshooting procedures mise CHAPTER 4 REPAIR AND REBUILD ~ 2 Section I wo a 7 ene ME Cleaning, inspection, and repair’ = 233 Wo Assembly = e502 'V Test and adjuntinens — susz 38 Vi Repair and rebulld standards sor 38 APPENDIX REFERENCES - 4s APPENDIX REPAIR PARTS LIST “ Section 1 Preface “4 General support and depot maintenance repair parts — a Figure 62 ‘Turbocharger assembly (7148000) - exploded view % 83 ‘ploded view 80 4 Turboctnger assemblies (10012636 and 59501-C~ 196353) - ‘onloded view 52 Section IT General support aad depot special tole 5 Figure 65 General support and depot special tools — M INDEXES 56 habetica, : 56 Feseral ok number = : 6 ‘Materiel agenoy and mandiacturer's past number ar ‘This manual supersedes TM 9-2090.201-35P, 8 January 1962; TM 9-2990-201-35, 21 February 1092, ‘the turbocharger portion of TM 8-2815-207-95, 10Jul) 1968; and TMt9-2615-204-28P, 29 May 1863.FIGURE SCHWITZER MODEL 40-554 (€3501-C- 199552) TURBOCHARGER. FIGURE 1, SCHWITZER MODEL 4-450 (746900) TURBOCHARGER, FIOURE 2, SCHWITZER MODEL 4-456 FIGURE 4. SCHWITZER MODEL 4-454C (Q0sSé279) TURBOCHARGER (s0si26sa) TURBOCHARGE:*€1, 1M 9-2990-201-45 DEPARTMENT OF THE ARMY TECHNICAL MANUAL "TM 9-2000-201-45 HBADQUARTERS DEPARTMENT OF THE ARMY CHaNoEs No.1 WASHINGTON, D.C. 20025, TURBOCHARGER, ENGINE ASSEMBLY 2990-074-8930 (SCHWITZER MODEL 4-456) 2990-974-7583 (SCHWITZER MODEL 4D-554) 2990-967-9909 (SCHWITZER MODEL 4D-454C) 290-999-2975 (SCHWITZER MODEL 4LE) curren a. iNTRODUCTION = i Baerbtion and Psy ‘curse 2 PARTS, SPECIAL TOOLS, AND EQUIPMENT FOR (GENERAL SUPPORT AND DEPOT MAINTENANCE 3. TROUBLESHOOTING Seton 1. Genera Section 1 General 1s ‘Satin 1 Gee urna 6 REPAIR AND REBUILD Secon TDinaembiy 1 Ceaning,Eapeton and ceair Mt, Reem Arron 1 REFERENCES Seton Introduction Figure 60. Turbocharger meombles (101260) and B01 Fgore i. Torbochargernesembly (OOUIB4) exp iew Figure #2 General support and depot sell tole is anal supersedes TM 8-280-201-3506 January 1962: TM 9.290.419, 21 Pebraay 19621M 9-2990-201-45 CHAPTER 1 INTRODUCTION Section L. GENERAL 1. Scope |, This technical mana contains instruc ‘ions for general support and depot maintenance of the Sehwvitzer Model 4-480. (1748900) 4-456 (Gos0szT9), 49-534 (63501-c-199552}, and 4D- 454C (10812698) turbocnargers. (igs. 1 throueh 4). ‘Themansal contains description of and prov ‘cedures for troubleshooting, enssetubly, ine Spection, repair, and assembly. b. Ampendix I contains a lst of current references applicable tothe turtochargers, & Appendix 1 contains an illustrated list of repair parts allocated to general support and Gopot malatenance 4, Notice of aiserepancies, or recommended hinges, shouldbe forwarded'on DA Form 2028 ‘Tank Automotive Center, ATIN: SMOTA-M, Warren, Michigan $8000, ‘This technical manual diters from TM 9- 200-201-85, dated 21 February 1062, TM & 2990-201-95P, dated & January 1062," and the turbocharger "portion ot "TM. 9-2615-201- 35, dated 18 July 1960, "and TA 9-2615-207-28P, ‘ated 25 Nay 1089 Sa follows (0) Combines generat support and depot maintenance instrections and repair purts lists in one mana, (@) Revises information on engine turbo charger “assembly, Model 4-450 (7748800), “for early "Continental Modet LDS-427-2 engines. (@) ‘cludes information on engine tur bocharger assembly, Model 4D-4S4C (10912858), foriate Continental Model 1DS-427-2 engines. (@) Includes information on engine tur- oeharger assembly,” Model 4-496 (Gos05270), Tor Miltary Model LDS 465-1 engloes, (©) Revises information on engin tur- bocnarger assembly, Model 4D-554 (@a001-C.139552) for Mack “Model ENDT-079 engines, ‘The pertinent vehicle operator's manuals contain operating instructions and maintenance ‘operations allocated tothe operator inperform= Ing mainéenance work within hs scope, ‘Tne _portneat_venicle organizational malitenance manuals contain instructions for ‘maintenance within thelr scope, 2 Genaal Support ond Depot Melntnence "hate “4 =P efor tothe pertinent vehicle organizational maintenance technical manual for the mainte mance allocation chat. 3, Forms, Records, and Reports For current and complete sting of al axe thorized forms, ‘refer to current tasve of DA Pamphlet 310-2, "TM 38-750 contains instruc tions on the use’ of maintenance forma, pertin- Ing to components covered i this mana Section I, DESCRIPTION AND DATA 4. Deeripion A, General. The turbochargers Gigs, 1 Uurobgh 4) are adapted for gasoline and diesel (mlttue) engine installations Turbochargers make use of eat energy that ie normally fost in engine exhaust gases. Exhaust gases, forced fut af the engine, drive a shaft and turbine tiheel (igs. 3 and 8) whieh diver the come bressor wheel. “The compressor la basicaly 4 Centrifugal blower that Increases’ velocity of fir entering engine intake manifoldb. Operation (tie. 1). Operation ofthe four smodns Ut farbothangers tg 8s follows: (© (Grbine housing through the exhaust {inlet on the housing ‘lows trough a set of notes Ting assembly. "These Stzzles increase the velocity ot the bine wheel - (2) Pressure of the exhaust gas is cone ‘erted into netic energy which ats 8 pon and drives the turbine wheel Exhaust gas then exite through ex find through the conventional exhaust Sytem ofthe vehicle ‘tae turbine wheel shaft, in turn Grives the compressor ubeel. Air Gnters at he center of the compres Sor wheel aad flows radially oxtwara fhrough a diffuser section and nto the “compressor housing. Com= pressed air leaves through a tangen- oulet in the compressor howsing and enters engine snake manlol FIGURE §. ‘TYPICAL TURBOCHARGERS 7749900 AND 10005279 - SECTIONAL VIEW.FIGURE 6, TYPICAL TURBOCHARGERS 10912638 AND 59591-C-190562 - SECTIONAL VIEW,& Lubrication (ig, 8), Labrieation of the same,” Tey are pressure lubricated [rom the meine lubricating system through external Di Ing from the engine oll gallery to the turbo fharger oll Inlet, Oil flows ito the bearing housing and then to the sleeve bearings and re tal line, On turbochargers 10812086 and 58591-C-199552, oll also flows dr fhrust bearing, "Two piston rings, loealed on the shat and turbine wheel prevent oll from ex Lid tering the turbine housing, Two plston rings, located on the thrust collar on turbochargers ‘7148900 and. 10998279, or located on Mager Bleeve on turbochargers 10912698 and 83501- ita9ssa, prevent ll trom entering the com= pressor housing. ‘These piston rings are not positive type seals, Piston ring (spe oll seals Ere used a each nd of the shaft and turbine thee] utzing air pressure from the compress {or directed Behind the rings to etfectively seal ott the ol 60 cara TYPICAL TURBOCHARGER - AIR FLOW DIAGRAM,© 2, 1M 9.2990.201-45, CHAPTER 2 PARTS, SPECIAL TOOLS, AND EQUIPMENT FOR GENERAL SUPPORT AND DEPOT MAINTENANCE 6. General Speci tools and equipment and maintenance parts over and above thove available to the using Organization are supplied to Ordnance general Support maintenance units and depot shops for [Posintaining and/or repairing the material, 7. Repair Parts ‘Repair parts are listed in Appendix 1 which is the authority for requisitioning. replacement parts for general support and depot mainte- 8 Common Tools and Equipment ‘Standard and commonly used tools and equip- ment having general application to this materiel are listed in DA Supply Manuals SM 9.4-4910- ABT, ASD, A65, and. AGB; SM 944-4940-A08; SSM 9.4-5180-AG1, A1T, A20, ASB, ASL, and A82; and are authorized for replacement by TA and ‘TOE. 9 Special Tools and Equipment Special tools illustrated in figure 82 and listed in table 1 are those tools necesary to perform the operations described in this technical man ual, oble 1. Spciat Toots and Bouipment for Generel Support ond Depot Maintenance = 3 wile we (GAGE, oe van apacing [aio a [aad 2 | Mera nace tenon as oe tio Heng om turbecharger 109852 PLIERS, tearing retaining ving | comassosy | 2 Compra the bearing byusing sleeve fdfor instalation FREPLACER, collar and com | gtansvoano4 | i, 59, and a2 | Replacing thrust collar or compressor SLEEVE, Shalt ving expander. jeroas6ues | ss ond sa | Ym 1809148) SUBBVE, thrat colar ring... |aeroao.2t22 | 52 and m2 ‘ostoie). | en turbecarscr 1098279 ony Socikr. wrench suachment, —|oiapeoedeza | a4 and s2 | Uh ith trae wrench thon1, 1M 9.2990-201-48 SPACER, seve clearance | cuo-evoaies | a and ‘Used ara dummy wheal when deter ‘hace. ‘amen ining he compro nc! bc cear SUPPORT, compressor whed dt 20 ana ot Support baring Bouing when re sens ing shaft and tebine whe cml1, 1M 9.-2990-201-45, CHAPTER 3 TROUBLESHOOTING $e Seetion | 10. Purpose 1. Information in this chapter Is for use of ‘maintenance. personnel. In conjunction with and as a. supplement to the troubleshooting section in the pertinent vehicle organizational ‘maintenance manual, It provides. continua on of instructions where a remedy in the organizational maintenance manuel refers to seneral support maintenance personnel for . Operation of a deadlined vehicle without 4 preliminary examination ean eavee further damage to a disabled component anid. possible injury to personnel By earefol inepestion and troubleshooting. such damage snd injury ean ‘oe avoided. Tn addition, the causes of faulty ‘operation of a vehicle or component ean often be determined! without extensive disassembly 11. General Instructions and Procedures ©. This chapter contains inspection and troubleshooting’ procedures to be performed after a disabled. turbocharger has’ been re- moved from the vehile, . The inspections made while the compo: nent is mounted in the vehicle are for the most. part visual and are co be performed before Attempting to operate the vehicle. The object Section 12. Troubleshooting Before Disassembly 4, Genera. Troubleshooting the turbo: charger before disassembly is essential in de termining what parts are unserviceable. and must be repaired or replaced during overhaul ‘The shatt and turbine wheel (figs, 8 and 6) sleeve bearings, and thrust washers are parts likely to show the most wear. Figures $ and 1 below, shew Luc necessary steps in deter mining excessively worn part. 1. Check Shaft and Turbine Wheel Roatat Movement. Champ the exhaust inlet ange of ‘the turbine housing in a softejawed vise, Ate GENERAL of these inspections is to determine the condi- tion of the component, and if found detestve, to take precautions to prevent any further damage, ¢. The troubleshooting performed while the component is mounted in the vehicles that ‘hich is beyond the normal seope of the using ‘ornization. Check the troubleshooting ase: tion of the pertinent vehicle organizational ‘maintenance manual, then proceed. as out- Tined in this chapter. ‘4, Inspection after the component is re ‘moved from the vehicle is performed to verity the diagnosis made when the component. was in the vehicle, to uncover further defect, or to determine malfunctions if the compo. nent alone is received by the maintenance es. {ablishment. ‘This inspection particularly Important in the last case because it is often the only means of determining the malfunc- tion "without "completely disassembling the component. , Troubleshooting a disabled component after it has been removed from the vehicle consists of subjecting It to certain specified tests. This chapter discusses those. symptoms which ean be diagnosed und interprets the results in terme of probable causes, TROUBLESHOOTING PROCEDURES tach a dial indicator to turbocharger with a clamp or magnetic base holier. Position dial Indicator point against fat of square end of turbine shatt as shown in figure 9. Check shaft And turbine whee! radial movement as follows: (1) Push both wheels sideways in direc tons shown by white arrows and note lowest reading while rotating wheels in alternate directions, Take readings from four sides of square fend of the shatt Push both wheels sideway’s as shown Dy Black arrows “and note lowest @1H 9-2990-201-45 reading while rotating wheels in flternate directions, Take readings from four sides of square end of shaft, FIGURE 10, CHECKING TOTAL END PLAY. 10912636 _and_53591-C-139552, rocemar @) Subract lowest vending trom highest Fading to obtain total radial more ment.” Maximum permissible shaft tnd turbine wheel rabvemetis 0, 023- finch. Refer to table for corrective procedure. €, Check End Play, Clamp exhaust inlet ‘aange of turbine Housing in a soft jawed vise ‘Attach a dial indicator to turbocharger with & lamp or magnetic base holder. Position dial FIGURE 9, CHECKING SHAFT AND Indieator point on endef turbine shaft and wheel ‘TURBINE WHEEL AND COMPRESSOR as shown in figure 10. Move shalt and turbine ‘WHEEL RADIAL MOVEMENT. ‘Wheel to extreme up and down positions to ‘heck total end play. Total end play should be Note. ‘To obtain total radial within 0,004 and 0,608 inch, movement of the compressor ‘Hh reer paar trkn= 12, Toblahooting Afr Duowenbly ‘changlr aid follow the sume pre Sedire.—Madimum permissible Troubleshooting after disassembly is basi- ‘Boremew is 0, 08einch for turbo: cally an nopecion of lntertal parts,” Refer to Ghargers —TH4B00G and 1003627) trouhleanooting table Cable 2) for malfunctions, Sno OLO0Sinch for Garbockargers, probabie causes, and their corrections.1m 95 2990-201-45 Se ee eee Malfunction Probable cnuses Corrective action 1. Compressor and turbine heels drag sp behind tar- | a; Disassemble and clean unit, ‘Assemble anit 1b Dirt accumulation behind | b, Disassemble and clean wait, compressor wheel. ‘Assemble unt Dirt causing drag in bear- | ¢, Disassemble and clean anit ings. And replace damaged parts ‘Azscnble unl 2, Shalt and carbine wheel and | a Worn bearings. Disassemble wt, replace compressor wheel radial bearings, andassemble wit, ‘movement exceeds hight fig. 9) Shaft worn. Disassemble unit, replace compressor wheel ad shalt land turbine wheel, and as- Semble unit. f Bore in bearing housing Disassemble unit, replace orn. Dearing Housing. 5, Bnd play exceeds 0,008-inch | _Tarust faces of thrust col- | Disassemble unit, replace (Gs. 10) lar on turbochargers 774 | thrust collar,” Dearing oF 8000 and’ 10035279, thrust | washers, and assemble unt bearing on turbochargers Yoo12608” and 5390i-C- 4150682, or thrust washers Bhd play loss than 0.008 ‘Carbon build-up behind tur- | a, Disassemble anil, clean inch figs 1 bine whet, ‘wheel, assemble wit, a b, Dirt accumulation behind | b, Disassemble unit, clean compressar wheel, wheel, assemble wit ‘5 Compressor end of turbine | a, Excessive intake restriction, | a, Gheckor clogged air clean ary fr (elerto pertinent vehicle operators manval). Replace the air cleaner elestent and lean the entire air intake System thoroughly. Check for collapsed intake tube and replace it necessary.Table 2 14 9-7990-201-48, ‘Troubleshooting - Continued Walkunction Corrective action ‘Compressor ond of turbine arty" Continued Tnauifiient air itration due to leaka inal intake piping Between air cleaner” and frbocharger. Operating under long ile periods in dusty areas, 1 Disassemble, clean, and as- ‘semble units” eer to per finent vehicle operators manual, : Disassemble, clean, and assemble unk, 6, Turbine wheel blades broken cf, tips missing, oF bent Failed engine parts entering turbine housing. ‘Whee striking turbine hous ing after bearing has become damaged or worn. 1 Clean entire exhaust aystem (Geter to pertinent engine maintenance and. Fepair ‘manual, Disassemble unit, Feplace’ compressor and furbine wheels, Assemble sit 1b, Disassemble, clean, and replace unserviceable parts fas! necessary. Assemble . Compressor wheel blades finer woes of broken off Foreign material entering air intake system and str ing wheel, Clean complete air intake system (refer to pertinent fngine maintenance and re~ pur manual). Disassemble &, Vanes of nozzle ring poened reducing “opening between Foreign vaterial entering turbine housing from engine exhaust inanifold or fale engine parts, Clean entire exhaust aystem (Geter to pertinent engine maintenance and repair ‘manual. Disassemble unit, Feplace’ nozsle Ting, and 3 ON ctoring compressor housing from bearing Rowse ine F Piston Finge worn or broken, Excessively worn ring lands onthrust collar & Disassemble nit, replace the thrust collar "json ings, ant assemble nit, by, Disassemble unit, replace thrust collar and. piston ings, and assemble” unit, 40, Off entering turbine hous {ng from Bearing howeing ‘Shaft and turbine wheel ple fon rings worn or broken, [Ring lands on shift exces- sively worn, @ Disassemble unit, replace piston rings, and’ assemble init Disassemble unit, replace ‘hait and turbine wheel and Baton rags, and assembleCHAPTER 4 REPAIR AND REBUILD Section |. GENERAL 14. Purpose 4, This chapter provides instructions for disassembly, cleaning, Inspection, repair, re- bulld, assembly and est and adjustment ofthe turbochargers after being removed. from the engine 2, Removal and installation procedures for the turbochargers are covered in pertinent ve- hile maintenance manials oF engine general Support and depot maintenance maa 15, Disssembly and Assembly hi A, Disassembly Instructions, Paragraphs 16 through St provide disassembly procesures forthe turbochargers, ‘The sequence of instrue~ Hons (1), "@),_and (9) for figures 11 through 39 indcates the sequence of instructions to be Tollowed for disassembly operations, B, Assembly Instructions, Paragraphs 36) through 80 describe only hose assembly ope- ations which cannot be accomplished by merely reversing the sequence of and procedures for Aistssembly. Where the assembly instructions fre the reverse of disassembly” instructions, Feference Is made to the pertinent disassembly Instructions, "The sequence of dsassembly in, structions (1), (@), and (@) Tor each illustra tion should Be performed in reverse order’ (@), @), and (1) inorder to perform the assembly procedure Section I, DISASSEMBLY 16. General Disassembly of tho turbocharger shoud be performed by following the paragrep instruc. tons and using illustrations as deseriptive rel Note. Disassembly procedures for_all Disassembly procedures _ turbochargers are the Sains ness Indeed sthorwise by the use-of lr fat nana 17, Cleaning Before Disatembly Before beginning disassembly, thoroughly wash the exterior ofthe turbuchar ger with dye leaning ‘solvent or” volatiie-mineral-sprit, aint thinner. ‘Thoroughly dry with compressed Bir ova clean dey cloth, Woming: Particles blown by compressed sur Bre eines cont ees Stream Ts not directed at We usetof any ther person he are 18, Removing Oi Inlat Adopter ond Oil Outlet "Cover=Turbocharger, 7748900 Only Remove oll inlet adapter and oil outlet cover from the turbocharger a8 follows A; Oll Wet Adapter, Refer to figure 11, FIGURE 11, REMOVING OR INSTALLING OIL, INLET ADAPTER TURBOCHARGER 7748000 (@) Remove two screws and lock wash- ers (A) attaching ol nit adapter {3) to bearing housing assembly. (@) Remove ol tet adapter (B) and apter gasket, Discard gashet1b, OM Outlet Cover, Refer to figure 12. (0), Remove two hex head cap serews and Tock. washers (A) attaching the oll outlet cover (B) tothe bearing hous @) Remove ot outlet cover (B) and FIGURE 12, REMOVING OR INSTALLING OmL ‘OUTLET COVER AND COMPRESSOR CAP SCREWS ~ TURBOCHARGER 7148000, @) Scribe ainement mares (C) on com- pressor cover, compressor housing SSsembiy, bearing housing seaenbly, ind turbitehounng to eure correct ostioing during as0ersy 4) Remove lockwire from compressor over ap screws Dy Remove eight ap screws and sealing washers Se uring the compressor cover to com Presber housing assembly. Discard Eealing washers and lockvires, 19, Removing Compretor Cover 7148000, Refer to figure (2) Compress compressor cover lock 1H 9-2990-201-45 ing (A) using retaining ring pliers - 10800178 unt Tock ring can be re moved {rom groove in compressor cover (le (@) Remove comprestor cover (). FIGURE 13, REMOVING OR INSTALLING ‘COMPRESSOR COVER » TURBO- ‘CHARGER. 7748000, Turbochargers 10995279, 10812698, and SUES? Refer to figuter id and iy (2) Scribe atinement marks on compres: Sor cover and. bearing hou ae Showa in figare 14. FIGURE 14, ON COMPRESSOR COVER AND BEARING HOUSING - TURBOCHARGERS 10096275, 10912636, ‘AND 9501-C-190852, SCRIBING ALINEMENT MARKSFIGURE 15, REMOVING OR INSTALLING COMPRESSOR COVER ~ TURBOCHARGERS 10985219, 10912638, AND 83801-C~130582 (2) Romove clamp mut (A, fig. 15) G) Remove compressor cover (By fi. 15) with clamp (C). Remove and dis- card compressor housing “packing from bearing housing on 10812698 nd 39501-C-199552, 20. Removing Compressor Extension Assembly Remove compressor extnsion assembly on turbochargers "TT48000 and 10805270. "Refer torigure 18. Note, Compressor extension on turbo- chargers TOUIDGI9 and S3SU1-C-TUWE2, Srintegra part of the compressor cover 28d is removed in paragraph 19. Remove and discard preformed packing ww 2b, Carefully pry compressor extension @) free trom dowel pin holes In compressor hous” Sngasrembly and remove compressor exes. Remove compressor cover lock rig (C). Remove and discard cover gasket (D). FIGURE 16, REMOVING OR INSTALLING (COMPRESSOR EXTENSION ASSEMBLY = ‘TURBOCHARGERS, 7148000 AND 10885279, 21. Checking Shaft and Turbine Weal and Com rotor Whee! Totel Rodel Movement 4 General, Chock total wheel radial move= ment ubing adil indteator before disassembling further. “This check is important at tls point during aisassemtly in order to determine how {idly the turbine shaft and sleeve bearings are sworn. This procedure wil assist during the Inspection (par. 38) tn determining what parts Checking Total Radial Movement, Refer FIGURE 17, CHECKING COMPRESSOR WHEEL TOTAL RADIAL MOVEMENT.(2) Mount a dia indicator (8) on housing Assembly and postion indicator point Against fat side of compressor wheel (2) Check total whet radial movement (Bin the same manner as directed mn paragraph 120, Note, Total radial movement smustnot exceed 0, 095-1eh on tare Bochargers THHBOO0 and 10095275, 4nd 0.088 Tach on turbochargers! TOOT265E and SUSU C8086 te raalal movement exceeds “ts Ii, heck tolerances of DIE Sia fesrings suraees, bering fang peli a 22. Removing Beoring Hovting Assembly Turbochargers 7749900 and 10095279, () Refer to figure 18; Position eight point, 9/B-tnch socket wreneh (A) on {quate extension of shaft and turbine Wheel, "Position 3/4-inen socket ‘French (B)_on compressor ‘wheel Jock nut,” Hold wrenches firmly to prevent slippage, "and posaible stm- tge to wheel ‘blades. (C), Remove ‘compressor wheel lock mi, FIGURE 18. REMOVING COMPRESSOR WHEEL LOCK NUT, (@) Refer to figure 19, Straighten tabs 18 (A) on four lock plates, Remove fight cap serews (B) and four lock plates. Note, On turbocharger 1099. 3216, scribe alinerent make od Se fslag se stor fire Gg Pa a FIGURE 18, PREPARING TO REMOVE BEARING HOUSING ASSEMBLY AND. RELATED PARTS - TURBOCHARGERS Tr48000 AND 10098219, @) Refer to figure 20, List bearing housing assembly and related parts (A) trom turbine ‘housing (8). It fight, insert two screwdrivers on oppotite sides. between bearing and turbine housings and pry upward FIGURE 20, REMOVING BEARING HOUSING ASSEMBLY AND RELATED PARTS ~ TURBO- (CHARGERS “7748000 AND 10095270,TW 9-2990-20) ‘moving the bearing housing ass07 Hiplace f onthe comprestor wheel ‘ie stown to gure 38, fo eliminate ‘he possTility-of davagine coms preveor veel ages bb, Turbocharxers 10512688 and 5$S01-C- sadBba, Refer to figure 21, (0) Remove compressor wheel lock aut as instructed In paragraph 22a(0), (2) Remove clamp mut (A) and position clamp (B) to center of beariag house fing being careful not to move bear ‘ng housing assembly Seribe alinement marks (C) on tur ‘bine housing ) and bearing housing G) to ensure’ correct. positioning duriag assembly. ® Litt bearing housing (E) and related parts from turbine Rousing). FIGURE 21, REMOVING BEARING HOUSING ASSEMBLY /ND RELATED PARTS - TURBO- (CHARGERS "10912038 AND S3501-C- 199882, Goution: tnunediately after rex ‘mofing the bearing housing as6ers ace onthe compressor whed) esembly” support 10809159, ‘Seshown in gure 33 eliminaré fe_posefbile of datvaging com poised bags 23, Removing Compressor Wheel and Shaft ond "Turbine Whee! ‘Turbocharger 7748900, refer to figure 22," checkalinemeat marks on shaft and turbine Wheel and compressor wheel, It the marks are not visible, proceed with subparagraph B(), below, and’ then make new marks before Bro” Ceeding with any further disassembly. {Gnas known ne net [ede Sate FIGURE 22, CHECKING ALINEMENT MARKS ON SHAPT AND TURBINE WHEEL AND COM- PRESSOR WHEEL- TURBOCHARGER. 774000, FIGURE 23. PRESSING SHAFT. AND TURBINE WHEEL OUT OF COMPRESSOR WHEEL ‘AND BEARING HOUSING.Refer to figure 28 ) Mount the turbine side of bearing sembly support = Support plates. 10699152 (A) and (@) Press shaft and turbine wheel (C) out of compressor wheel thrust collar ‘Assembly. and. bearing housing as Sembly ustng an arbor prose (2) avtion: Hold hand under shaft and Tarbine Wheel when pressing Sotto prevent shat-andtorbine siheat rom fall (8) Remove shaft and turbine whee! (C) @) Remove compressor wheel (D) and shims from behind wheel, Note {nlelness of shims and record for use during assembly. (©) Remove bearing housing (E) from ar- " 1 9-2980-201-45 ‘or press and disassembly support - Tossa, On turboenargor _774e snd shat 5000, compressor wheel and ivbine heel Tors a balanced (©) Remove clamp rom bearing housing On turbochargers 10013626 and Sasoi-c- 130598 24, Removing Shaft and Turbine Wheel Rings Remove piston ringe from shaft and tr whoolusing Snapring pliers. Refer to figure 24 Note, After all disassembly bas een erforined relatlig f the eonpresear vie ‘Ehd shale and turbine wel" s0- Wat Those [HUES can be elely stored to prevent Gamage i iiat wines, ie tate nog aioe REMOVING PISTON RINGS FROM SHAFT AND TURBINE WHEEL,25, Removing Compratior Housing Assembly ‘1 Compressor Back Plate Removing Compressor Hovsing _and Tofst Collar Assembly = Turbochargers asooU and 105279, cougmson 1 ©) Reter to figure 25, Remove four focket-head cap serowsy_ lok vash= fs, and flat wanes (a) ataching CGtressor housing assembly ‘Searing tousingaxscibly. Separate compressor hoteng @) irom bearing / fouring assembly. 2) Refer to Sgure 26, Remove flat thrust washer (A), thrust collar as sembly (B), and Spring washer (C). Note, On turbocharger 714 00d, the Chrust colar asaanly ‘San Thsoparable un whereas, on turbocharger T0808279, it con FIGURE 28, REMOVING COMPRESSOR HOUSING ASSEMBLY - TURBOCHARGERS 1 ‘rago00 AND 10985278, é, Si A counting tit os ere FIGURE 26, REMOVING THRUST COLLAR ASSEMBLY AND RELATED PARTS - TURBOCHARGERS 7743000 AND 10088270,b, Remove Compressor Back Plate Ase sembiy = Turbochargers 10012696 and 9380 CUES, (0) ‘Turbocharger $3501-C-180562, Rex Torte figure 21, Scribe allnentent marks (A) on compressor backplate and bearing nousing to ensure cor= ect positioning during” assembly. Remote locevire (B) from compres” sor tek plate ‘cap serews (C) and Femove five cap screws. and sealing washers (Ch, Discard sealing wash= rs. and lockware,, Remove com pressor buck plate (D). FIGURE 28, REMOVING FLINGER SLEEVE. ASSEMBLY AND ASSOCIATED PARTS FROM COMPRESSOR BACK PLATE - TURBOCHARG- "ERS 10912038 AND 53561-C-130052, 26, Removing Thrst Collar or Finger Sleeve Piston Ringe Remove piston rings from thrust vollar or finger sleeve using snap ring pliers, Refer to FIGURE 21, “REMOVING COMPRESSOR BACK PLATE, ASSEMBLY - TURBOCHARGERS 10012638 AND 53501-C-190882, @) Turbocharger 10912858, ‘The pro- cedure for removing the compressor ‘back plate assembly for this nit i= the same aa in sibparagraph BO), above, except that the unt utilises {our ap screws. and two lock plates In place of the five cap screws and sealing washers, "and the lockwire, Straighten the fock plate tabs and then remove the eap screws and loc plates to remove the Bick pate, ©) Turbochargers 10912698 and 59501 80052, | Refer to figure 28, Ree Imave compressor housing packing Gr anger steers 3) ad sis FIGURE 20, REMOVING PISTON RINGS,27, Removing Front and Rear 0 "ond Associ Remove the front and rear ofl retainers and associated parts on turbochargers "10012698 nd 39501-C- 139553, Note. Turbochargers 7748000 and 1092- sa) ao hot have oll ears, a, Refer to figure 30, Straighten tabs se curing three cap screws (i) and remove screws, Remove lock plate) and oll detector (C). FIGURE 30, REMOVING OWL DEFLECTOR - ‘AND 83591-C- 139552, 1b Refer to figure 21, reiainer (0), Remove front oll thrust ring’ (B), thrust bearing FIGURE 32. SLEEVE BEARING, AND EXTE (©), agacer, sleeve (D), thrust ring (2), and FIGURE 31, REMOVING FRONT AND TREAR OIL RETAINERS AND ASSOCIATED PARTS - TURBOCHARGERS 10812886 AND 83801-C~190882,, 28, Removing Rotor Shot Sleeve Baarings ond ld Ports Turbochargers 7748900 ond 10728279. 2, Turbochargers 7749000 and 10908279, Refer io figure 32. @) Remove and aiscard ousting gasket (A)- (@) Remove sleeve beating thrust wash- er (B) and sleeve bearing (0), (8) Remove external shield (D). REMOVING OR INSTALLING COMPRESSOR HOUSING GASKET, THRUST WASHER, (AL SHIELD - TURBOCHARGERS 7748500 AND 10605279,b, Turbocharge 33. 11748000, Refer to figure (a), Remove retaining ring (A) from com= pressor ‘end of bearing. housing 25- embly using retaining rag pliers 10498808 (2) Remove retaining rng (B) from tur~ Dine end of bearing housing assembly ‘ong retaining ring plers~ 10805506 land then remove thrust washer (C) 4d sleove ‘bearing (). "Using the Same pliers remove the last relain- ing ring (2). FIGURE 33, REMOVING OR INSTALLING. RETAINING RINGS, SLEEVE BEARING, AND ‘THRUST WASHER TURBOCHARGER 7148000 FIGURE M4, REMOVING OR INSTALLING RETAINING RINGS, SLEEVE BEARING, AND THRUST WASHER - "TURBOCHARGER 10885218, Turbocharger 10088279, Refer to fig- weds, () Remove retaining rings (A and B) ‘ing retaining Fing pliers 10008898 1H 9-2990-201-45 land then remove sleeve bearing (C) ‘and thrust washer @) ) Unig te same ters, remove the 5 Fetaning ring (2). 29. Removing Retor Shaft Slave Bearings ond “Ausocieted Port—Torbochorger: 10912638 ond $3591.6-199582 a, Refer to figure 35, Remove rotor shaft sleeve bearing (A). Remove retaining ring (®) “sing bearing retaining ring pliers ~ 10033608, FIGURE $5, REMOVING OR INSTALLING ‘COMPRESSOR END SLEEVE BEARING AND RETAINING RING - TURBOCHARGERS. 10012888 AND 89501-C-199652, , Reler tofigures6. Remove retaining ring (4),” rotor shaft sleeve bearing (B), bearing thrust washer (C), and retaining ring 0). Coe pliers” 10905908 to remove retaining rings (A iad). FIGURE $6, REMOVING OR TNSTALLING TURBINE END SLEEVE BEARING, THRUST "WASHER, AND RETAINING RINGS - TUR- BOCHARGERS. 10012698 AND 59591-C- 18958230. Removing Nettle Ring Remove nozale ring from bearing housing as shown in igure 37 for turbochargers T746900 nd 109005279, ring 1s Ught on housing, ie Serta sharp ‘edge blade under the ring flange, Tap blade lightly, going completely around ring, wail gap is sufficient to receive screwdrivers Insert two. screwdrivers ‘on opposite ides a ing and pry upwards against flange wnt abe to remove the fing. On turbocharger 7748900, the nozzle ring. 1s not piloted on the bearing housing and is to be removed from the turbine Remove pale, and intersal” shield turbochargers ‘rra8600 and 1099827, "Refer fo figure 36. Fetaining ring, noztle back (0), Remove retaining ring (A) using snap Fig pllers = 10005588, @) Remove nozzle back plate (8) (8) Remove internal shield (C) on turbo- charger "7748900 only. 2 Remove retaining ring and turbine back ple «turbochargers 10019896 and S8591- C5 198602, "Refer to figure 29, () Remove retaining ring (A) using snap ing piers = 10008898, ) Remove turbine mck plate (B) FIGURE $8. REMOVING OR INSTALLING RETAINING RING, NOZZLE BACK PLATE, AND INTERNAL SHIELD - TURBOCHARGERS "7748900 AND 10835270, FIGURE $8, REMOVING OR INSTALLING RETAINING RING AND TURBINE BACK. PLATE - TURBOCHARGERS 10012098 “AND 59501-C-190582,16 9-2990-201-45 Section Ill CLEANING, INSPECTION, AND REPAIR Cleaning Alter disassembly and before inspection, all tarts must be thorowshiy cleaned and dried by leaning procedures used atthe unt performing the repair operations, Clean all meal parts ‘with volaile-mineral-spirits. paint thiner oF “Gryecleaning solvent, Refer to TM 8-247 for otter related materials, Note evr wa cure soaion wige Seg ue ape ee SrashoF plastic seraper ofl. 23, inspection and Repair 2, General, All parts must be thoroughly coaiined an inspected to determine if they are Suitable for rebuild of the aasembly or if they most be discarded and new parts substituted, Some types of woar or damage may be detected by visu ingpection and other types require the use of suitable measuring instruments,” ALL parts must meet the repair and rebuild sande Ards et up in paragraphs 54 through 66. 1b, Compressor Cover. (1) Carefully inspect compressor cover {or cracks, distorted flange, and damaged mating surfaces. 2) When compressor cover shows signs of distorted mating surfaces of lange, cover must be replaced, Slight nicks fon mating surfaces can be removed ‘sing fine mil fe, ‘& Compressor Extension. (0) Inspect compressor extension as- bly for cracks, broken vanes, land loose dowel pins. Make sure preformed packing fits properly in Eroove and hat retaining groove is ot damaged. 2) Nloks or slight scratches on mating ‘surfaces of compressor extension ‘can be removed using a fine ml le fr crocus cath, Replace dowel pins that are damaged, @) Uf dowol pin notes in extension are lversize and pins fit loosely, replace ‘compressor extension assembly, 4, Compressor wneet, (0) Inspect compressor wheet for bent, tracked, of missing blades, It Importantto check closelyfor cracked binges. Cracked blades will Brest uring’ operation and eause severe fdamage to the compressor extension fnd housing. (@) Check shaft pore in compressor wheel against Kimits specie in the Tepr and rebuild standards (pr, 58), Mf the compressor wheel, on turbocharger T748800, ie damaged, It will be necessary to replace the ‘compressor wheel and the shat and turbine wheel aaa unt because they fare only available in 4 balanced se sembly. Compressor Housing. Assembly or Back (1) Inspect the compressor housing oF bmck plate for cracks and damaged Mating surfaces. “Inspect face be- hind compressor wheel for exce sive wear or scoring. Check tore af ‘compressor back ple against Limits Speciliedin repair and rebulld stand Ards Gar, 63). Check bare of insert {in compressor housing against limits Specifiedin repair and rebulld stand ‘ds ar. 54). @) Replace compressor housing assem- bly or back plate when piston ring ore surfaces are’ scored or not within Speciied limits Not._Neveratemgl to wld 2 foarte or bak pleas ls my ao fer aaiag sataeee ad Saas striae ae SpE etal weer or €) Remove slg scratches and scoring from face of compressor housing ot Tuck plate using crocus cloth, Re-1M 9-2990-201 move allraised metal from compres: sor cover gasket surface and com Bressor housing gasket surface, @) When the insert sn the compressor housing ‘of turbochargers 7248000 nd 10805279, does not mest speck fication indicated in repair and re build standards GSA), replace the compressor housing. ‘4, Flat Thrust Washer = Turhocharsers ‘1id900 and 10005779, (Refer to figure 40, (4) Inspect Nat thrust washer for scored surfaces and dlatorted conition, Check flat thrust washer again Limits specitid in repair ana rebuild standards (jar, 81), Examine thrust faces for scores of deep scratches, Check thrust sher for distortion, FIGURE 40, CHECKING FLAT THRUST Wasi THICKNESS - TURBOCHARGERS 7748000 AND 10986279, Py @) Place flat thrust washer (A) on a ‘at machined surface, (©) Attempt to insart a 0, 002-inch feeler” gage (B) between thrust surface of thrust washer and Tat machined surface, "Cage should not enter between washer and fat Surface when washer is pressed Tightly against “the flat surface, (©) Measure fat thrust washer with micrometer, Thclmess should ot e Less tin 0, O02-inch and be parallel witin 0, 002-ineh (C) @) Theat thrust washer must be re- pliced when found unserviceable, Slight seratenes and seores ‘can be removed by ‘using. crocus cloth Thrust washer must conform to COLL frances shown in figure 40, 'ER FOR DSTORTION AND PROPER1H 9-2990-201-45 & Spacer Sleeve, Thrust Bearing, and (©) Check plton rag grooves for shi Biggs Sersboargess OLR ed srenre ‘A thrust collar assembly fe Having worn piston ring grooves ‘ust be replace (2) Inspect the thrust bearing and thrust ings for scored or scratched sur~ (@) Check shatt tore in thrust collar faces, Cheek spacer sleeve bore ‘Renae Limite apeesied ln repair and Glameter and Length galt. Limits PEpanld standard (par. 58). Replace Specltedin repair and rebulldstand- ssenibly when bore size 18 not With ‘bdo (par, 61), Check thrust bearing {in specifications. Tength between bearing surlaces eainat limite apecfied ia eepair and, Flinger Sleeve = Turbochargers _1001- ebuild standards (oar. 62). Check 2686 and $9591-C= 159552, frustesag bore diameters and teks nesses againat mite specified in re () tnapeet finger sleeve for scored or fair and rebuild standards (par, 60). Seratehed surfaces, Inspect outside Replace epacer sleeve, thrust bear ameter inting groove area. for ing, or thrust rigs hen ot athiA frurned spots oF evidence of rubbing specifications. fganat bore in compressor housing. isodamaged, replace trust collar. (2) Replace thrust bearing or thrust rings Sight seratehes are permissible, MU thereare deep scores or scratches. Roplace sleeve if grooves are dam= Slight scratches canbe removed from aged. fhrust ings by using erocus cloth, (2) Check shatt bore in finger sleeve urust Collar Assembly = Turbocharger ‘Againat limite apecled in repair and ebuild standards Gar. 62). Replace Flnger sieeve’ when tore size fs (2) Inspect thrust collar assembly for ‘within specifications. worn oF scored trust surface Tapect ‘outside. dlameter in ring J. leave Bearings and Thrust Washers. fgroove area for burned spts or evi= ‘ce ofrubulng against bore tn com= (0) Inspect rotor shaft sleeve bearings [pressor howsing, if so damaged, re find sleeve bearing trust washers place thrust collar, Make sure for scratches and. worn surfaces fhrast surfaces on ‘flanged. thrust Wien sleeve bearings and. thrust ‘washer and thrust collar are smooth, ‘ashore thow evidence of wear, they Slight scrstehes are permissible, tut be replaced, Check sleeve Check collar assembly against limits Dearing bore diameters against Lim Specliied in repair and rebuild stand Ae specified in repair and rebulld ards Gar. 38) Standards par. 50 for, turbochars> fers, 7748900 and 10095279, or par. (@) Check thickness of thrust washer 68, for turbochargers 10012688 and Seainst limite specified in repalr 53501-C-180882). Chock thrust ed rebuild standards (ar. 38). swashers against limits specified in Gheck this dimension at several (epur and rebuild standards par, positions around washer. The Sofor turbochargers 7748900 and Efrust surface in the cupped por= 430008279, par, 6¢ for turbocharger on of the. washer cannot be 58801-C-190852, or par. 98 for tu fmeasured unless washer Is. re- oenarger 10912888). ‘moved. Disassembly ofthe thrust Collar” assembly is ot recom (2) Replace sleove bearing and thrust Shended, When thrast surface In trashers inspection shows exces= upped portion of ashe appears tive wear or they do not meet specl= ta'be worn, replace the assembly. Heatione of the sepalr and vevulld 24 9-2990-201-43 standards, Slight seratehes can be emoved from thrust washers using rocus cath, Bearing Housing. (0) Inspect nearing housing for cracks and damaged or soored bore, Check bore in housiag against iimits specte flea in repair and rebuild standards (Gar, 88 for turbochargers 7748000 and 10385279, oF par. 86 for turbo Chargers 10912636 "and. 59501-C- 199882). Piston ring bore tn bearing housing’ must not exceed 0. 87-inch, Replace bearing housing i damaged, (@) Remove all raised metal_on ma- chuned surfaces osing. 4 fine lll file. Do. not attempt "welding. & racked housing. When cracked, replace housing Nozzle Ring, (4) aspect nozste ring for diatortion and broken weld Joints, Make sure rane are not bent oF ow of linemen with fen other. Check spacing of norte Bie Rates cans ing vanes on turbochargers 7748900 and 10505278, "Refer to figure 41, (@) Position nozzle ring (A) on a flat surface, ) Cneck spacing of vanes (8). Use nozzle vane spacing gage ~ 108% 5183 on turbocharger 7742000, Use nozzle vane spacing gage 10951060 on turbocharger “1089— 5219,.Tae "a0 go" end of EOE Should not enter’ space between vanes, "The "go" end of age ‘should enter apace, (©) On turbochargers 7748900 and 10036279, correct slight varia Hon of “spacing using pliers, Straightoning vanes is not recom ‘ened when severely bent, Note. Norse vanes on t= socks “SST e-ISE, re cas an Gann bo serene 2) When the vanes are severely bent oF damages, replace nozsle Ting, FIGURE 41, CHECKING SPACING OF NOZZLE RING VANES - TURBOCHARGERS 7748900 AND 10995279,1m 9-2990-201-45 Shaft and Turbine Whee! Aistortion, or other damage, Post tion "shield on a flat surface and Note, On turbocharger 7748900, Inspect for warped flange, Replace ‘the Shalt_and turbine Heal and shield when distorted or warped, Gompressor wheel form a talanced ‘Geeuntys The ‘complete aaseny (2) Slight raised metal on mating sur uae be replaced Weiher pase Te {aces can be Femoved wing a fine (area tgiseenae mill Se, "Do not weld of braze tracks, Replace internal shield when (@) Inapect shatt and turbine wheel for cracked, broken, “bent,” or missing blades, Repairs are ‘not recommended ot p,_Nogsle or Turbine Back Plate, shaft and turbine wheel," ‘Therefore, if any” broken, best, oF missing (@) Inspect nozsle or turbine back plate blades are found, the’ shaft and tus for eracks, datortion, or other dame bine wheel should be replaced, Lac age. Position back ‘plate on a fat spect piston ring groove walls for Surface andinspect for warpage, Re- Seoring, Minor scratches are ace place. back plate when storied oF ceptable, Inspect the. platon ing warped, trooves for wear. Slight ralsed metal on mating sur @) Check diameter of shart against faces can be removed sing a fine Tints spected in repair and rebald ‘mill file. Do not weld oF braze Standards ar. 55 for turbocharge racks. "Replace nozzle back plate fers 7148900 and 10095279, or par, shen cracked, 6 for turbocuargers 10912038 and 53081-C-188552). Replace shaft and Extornal Shield - Turbochargers_714- ot met. for bends oF damage, Straighten bends a8 re= aquired. ‘ay Turbine Housing, Clamp Assembly - Turbochargers 1038- (©) Inspect turbine housing for cracks, 5279, 10912636, and SHB01-C=190552. Tnapect istorted exhaust outlet flange, and clampassemblite for strippedthresds and dar @amaged mating surface, Make sure Sged.°V" mands, Replace clamp assembly it ‘ny threads are in good condition, any damage exits, Check interior of housing for evi” dence of turbine wheel blades con a, OU Deflectors = Turbocharguts _J091- Ucling concave surtace. When this 2638 and S3801sC~i30582, "aspect the ol de= condition exists, check sleeve bear- {lector for eracked, broken, or mutated loskc Ings ‘or wear ‘as directed in para~ ing tabe, Replace oll deflector if tabs ctonot graph 33), De used fo Lock tabs. (@) Repair any damaged threads in hous- _t,_ OWL Retainers = Turbochargers. 10912698 ing wilt a used tap. Remove raised and'5501-C-190582, Cheek tating surfaces of etal and slight seratches on mating Oil retainers for burs, Bure on these surfaces Surface using. fine mill file. Do ean be removed by lapping on fine emery cloth, fot attempt to weld or braze the ‘The area adjacent tothe hole on fat surface of housing. Replace housing when it the rear oil retainer is a bearing are cannot be repalred, At for, nicks, scratches, and. burs,” Minor Scratches of burs ean be removed by lapping Internal Shicld - Turbocharger 7748900, this surface on crocus cloth. If surface is exe cessively scared or scratched, replabe rear ol (Q) Inspect internal shield for cracks, Fetainers aSection IV. ASSEMBLY 24, General A, Assembly Instructions, Paragraphs 36 threigh 50 are supplemented with lustrations, figures 42 through 61, that depict only those assembly operations ‘which cannat be accom: Dlished by merely reversing the sequence of nd procedures. for disassembly. Where the Assembly instructions are the Peverse of the isassembly instruction relerence 18 made to the pertinent disassembly” instructions, The sequence of disassembly instructions (Ci), (2, and (@)) for each paragraph atould ‘be per formed in the reverse order (3), 2), and ()) to accomplish the assembly procedure Note. Assombly procedures for all smodee of ihe Gee re are Tae aa ‘less ndeated otherwise by the Taclaaioe helt respective model numbers. b, Cleanliness During Assembly, ‘The tur- bocharger is @ precision product ad extreme fare and cleanliness. must be exercised in all phases of assembly operations to ensure satis- factory engine performance, Dirt and dust, ‘even in minute quantities, are abrasive, Alte? ‘leaning and inopeclu and fort Defoe ‘ech [But is assembled, coat sleeve bearings, shalt Journals, and all contact suriaces with engine ‘il (OE). ‘This will ensure sufficient lubrica- ton of moving parts when nit is first pu into ‘operation. 235. Replacement Kite Many ofthe components ofthe turbochargers are supplied in the form of ite, These Tits and their components are Hated in Appendix I Whenever a turbocharger te rebuity the Kits should’ be otsained and all of the kit contents Should be used, 6. Installing Rotor Shaft Sleeve Bearings ond "Autoccted Port Turbochorgere 17748900 and 10935279 Refer to paragraph 28 and e and reversethe sequence of instructions to iaatall the rotor shalt sleeve bearings, rust washers, and re- taining rings.” Do not install the parts covered fn paragraph 26a at this Lime, ‘These parts will be installed late Note, When installing retaining rings, male certaln fat side of eich Ping cee ‘spective bearing and tat the rings ae Eeperly sated ntieir eoress Rotor shaft Sleeve Bearings and “Astoioted Parts—Torbocharger:, 10912636 and 59591-¢-199582 ”. Refer to paragraph 29) and reverse the se- quence of instructions to install the rotor shalt Sleeve bearing, thrust washer, and retaining Note, When installing retaining rings, snake certa fat ste of a0 Png ces ek opeetie_bering_aa hat the Tings ane Bopery sated intr esres 38, Installing Internal Shield, Turbine and ‘Norse Boek Plates, ond Retcning Ring ‘a, stall Internal Shield on Turbocharger ‘1748060 Only, Nozzle Back Plate and i Plate and Retaining ‘Ring on Turbochargers 1748000 and 10995278, Referto paragraph Sia andreverse the sequence of instructions, al Turbine Back Plate and Retain Rung on Turvochargera 10912098 and S9591-C 50852, Refer to paragraph $1b and reve ‘he sequence of instructions. 239. Inaaling Neral Ring in Turbine Hovsing Uustall nozzle ring inthe turbine housing in turbochargers 1748900, 10955279, and 53901- (05190652, Retor to figure 42, Install the shaft and turbine wheel and piston ings in the turbine housing, ‘The procedure is the same for all model turbochargers, Refer to'tigure 48 which Ilustrates the procedure on turbocharger, 2748000, (Clamp turbine housing (A) sn vie, B, Place shaft and turbine wheel (B) in turbine housing (A)FIGURE 42. INSTALLING NOZZLE RING IN TURBINE HOUSING - TURBOCHARGERS FrguRE 49. ‘TURBINE WHEEL AND PISTON RINGS (ON TURBINE HOUSING, INSTALLING SHAFT AND "7148000, 10885279, AND 59901-C-139352, & Place shatt ring expander sleeve - 1ogB0148 (C) over shat 4 Install two new platon (raves of shaft {eo degrees apart, ings (D) into Foate rings until gape are Remove expander sleeve - 10899148 (B). 41, Installing Bearing Housing on Turbine Housing ‘a, Turbochargers 7748900 and 10995270, () Reter to figure 44 (@) Apply a ent coat of engine oft (GE) to shat and piston rings (A), Make certain the piston ring gap fre 160 degrees ayart_ and’ they fre centered on shaft and turbine(0) Place bearing housing (B) over Note w pston rings do nat Shalt and piaiion on tarbine ect Tea ia touain casi Rousing. Make sure”alinement Semove" Rousig” and" recente? mmanaa, made during disassembly He Gn turbocharger "748000, Tig. 1) ae sine (2) Retort figure 45, (@) Position external shield (A) so that. alinement mark agree with mark on bearing housing “made (uring disnasembly (ig. 1). Note, The cut-out portion of she external shields! clear the ‘UFDIne Housing mounting lange: (b) Secure external shield and bearing housing with four locke plates and fight cap serews (8). Note, ‘The added length of tne Soe wrench ada ST ibaa inereaee foc fever arm aad thereby decrease posite 8 pom 1.5 pound-feet. iden olf Tet boast 183 FIGURE 44. POSITIONING REARING HOUS- pomareertorges ING ON TURBINE HOUSING - TURBOCHARG- "BRS 7748000 AND 10835270, FIGURE 45. SECURING BEARING HOUSING AND EXTERNAL SHIELD ON TURBINE, HOUSING - TURBOCHARGERS 748000 AND 10995270, 20(©) Tighten cap serews to 17 pound fect torque, Use box wrench adapter = 6722922 (C) only to Gate cap seven under lite (@) Install bearing (C, tig. $2) and {hrust washer {B) in bearing hous ing. Th some instances ‘only ane fend of the bearing Is grooved, if {his ts the case the grooved end ‘ist be facing out suis, (0) Reter to figure 46 @) Apply a tient coat of engine ott (Gb) to shat ana piston rings (8), Mae certain the plston sing gps are 160 degrees. apart and. cen fered on shalt and turbine wheel (b) Position clamp (B) at the center of bearing housing (C) (©) Place bearing housing (C) over Saft and position on turbine hows ings making contain allnement mark) are alined ‘Sovehousiy anivecontersige FIGURE 46. ING ON TURBINE HOUSING - TURBOCHARG- POSITIONING BEARING HOUS. ERS" 10912638 AND 53501-C- 130052, 2) Reter to figure 47. Position clamp (A) on bearing and turbine housing flanges.” Using a. sultable grease, lubricate back face” and. threads of lamp nt (B)netall not and ghten tora torque of 10 pound-teet. Labri- cate and install bearing (A, fig. 98) at ‘compressor ehd af bearing pousing FIGURE 47. SECURING BEARING HOUSING (ON TURBINE HOUSING - TURBOCHARGERS 10012698 AND 59501-¢-190882, 42, Inaaling Front and Rear Oil Retoners—Tur- ‘bochargers 10912638 and 53591-C-199552 ‘Turbochargers 7748000 and 1000 a1) 0 not ave ot a. Refer to figure 48. Position rear oi! retainer (A) on bearing housing with plain face fgainst housing making certain the three aere%: holes. are alined. Place thrust ring (B) and Spacer sleeve (C) over Fear ollretainer. Labri= fate thrust face only FIGURE 48, PLACING REAR OIL. RETAINER, "THRUST RING, AND SPACER SLEEVE OVER BEARING HOUSING - TURBOCHARGERS 10912658 AND S3901-C-190982,b._Reter to figure49, Position thrustbear tng fa) over spacer sleeve with oil passage hole faeing retainer. Place thrust ring (B) over thrust wearing. Position fron oll retainer (6) fver thrust ring with recessed ace. towards thrust bearing holes are aline, FIGURE 49. PLACING THRUST BEARING, THRUST RING, AND FRONT OL RETAINER 10912688 AND 53591-C-199552, Note. Whon properly positioned, evtawa tion i Both retainer sll be oy if rath Hide of bearing Bousg “ee Refer to figure 50, (0) Position oll detector (A) over cut FIGURE 50, INSTALLING O1L. DEFLECTOR. LOCK PLATE, AND CAP SCREWS - TURBO. (CHARGERS {0912638 AND 59501-C- 130852, away portion of oil retainers and line ‘erew holes, Position lock plate (B) over remlning screw hole, 2) Secure assembly serews with three cap “Torque tighten screws fo ive pound-feet,» Bend tabs tgalnat cap screws, 4, Install thrust collar assembly, piston ings, and compressor housing on tutbochany fra 748900 and 1093527 (0), Reter to figure 81 (a) Insta at tnrust washer (A) over Salt with machined thrust face Sp. Unbricate thrust face with ‘engine all (OF). FIGURE 51. ASSEMBLY OR FLINGER SLEEVE ON SHAFT ‘AND TURBINE WHEEL - TURBOCHARGERS "748000 AND 10095270, PRESSING THRUST COLLAR(0) On turbocharger 7748000, ube ‘Sseembiy (B) mith engine ofl (OF) find place assembly with thrust (©) Onturbocharger 10396278, place thrust ring (C) over thrust washer (A)... Lubricate throst face of {thrust washer (D) and position over thrust ring. with machined fice down. Install Slinger sleeve and shaft™ with piston seal ring srooved end up, (@ Position turbine wheel support = 10800151 (F) on arbor pres (©) Ifinger sleeve is tight on shat uae berg Bouin sembly fension of shaft and turbine wheel esting on support ~ 1080051 (8, Coution: Do-not press tur. (ar in Tarbine housing © Position collar and compressor ‘wheel replacer 1089914") (©) Press thrust collar assembly (2) for’ turbocharger 1148000, oF ‘inger sleave (E) for turbockare- fr 10808279, "on shaft unt ik Bottoms agalnst shoulder on shaft (2) eter to figure 2 @) Clamp unit in a vise on, turbine ‘ovsingtmountng Hange (A) (©) Place collar ring expander sleeve = 10898140 (B) over tarust collar ‘Assembly oF finger sleeve (6) Install evo new thrust collar pis= fon rings {C) into two grooves of thrust collar assembly or linger fire 180 degrees apart, ‘Labrieste ‘ngs with engine oi (OE) Toessi49 Be FIGURE 52,_ INSTALLING PISTON RINGS (ON THRUST COLLAR ASSEMBLY OR FLINGER SLEEVE ~ TURBBCHARGERS "748000 AND 10098270, (8) efor to figure 53. a . (@) Bend tabs on four lock plates Securely against the heads. of ‘ight eap screws (A), (©) Position new compressor housing fake (2) on aling aurlace of bearing housing. "Make. certain ferew holes and oil drain passage Ingasket and housing are allned riguRE 59. SSNRUST COLLAR ASSEMBLY ~ TURBO. INSTALLING COMPRESSOR ‘CHARGERS 1148000 AND 10095270,(©) Position spring washer (C) over thrust colldraasembly and against ‘Hanged thrast washer, 4). Refer to figure 54 (@) Center piston rings on thrust Sollar and make Certain Ping gap fre 180 degrees apart. (©) Position compressor housing (A) ver shaft and turbine wheel and Aeshna compressor housing ease (ig. 12) are ained. nud compressor rots ‘sity remove Rowing and ree (©) Secure compressor tousng, to washers, lock washers, and soe- Ketehead eap screws (6), Torque Lighten cap. screws to” 20 pound fect using torque wrench (B) and 42, Install piston ing, alate preformed. packing, tack plate on turbochargers Sa501-c- 130859, compressor back 10912838 and FIGURE 54, INSTALLING COMPRESSOR HOUSING ON TURBOCHARGERS a (0). Refer to figure 58 (@) Position ninger sleeve (A) over fl deflector’ with piston ring iroove end up. salt fade Gat an arta Ele igre 66 enove FIGURE 58. ‘AND PISTON RINGS ~ TURBOCHARGERS 10012638 AND £9801--190082, INSTALLING FLINGER SLEEVE ‘748000 AND 10995270,(©) Place collar ing expander sleeve = 10800147 (B) over finger sleeve (©) Install two new piston ings () into groove af finger sleeve (A). Foate rings until gape are 180 de- grees apart, Lubricate rags with fngine ol (2) (@ Remove sleeve (B). collar ring expander @) eter to figure 56, (@) Place packing in mating surface ‘roove of compressor tack plate & (©) Center piston sings on singer Sleeve ahd make certain the ring aps are 10 degrees apart (©) Position compressor back plate over shaft and turbine wheel aad Against Dearing housing. Make certain seribe’ marks (B) sare Note. if piston rings do not gute compresaor ous ‘Sily,_remove back pate and ‘center rings @ Onturbocharger 52501-C-199552, secure compressor tack plate (0 Bearing housing with five sealing washers and. cap" serews (©), FIGURE 56._NSTALLING COMPRESSOR BACK PLATE AND PREFORMED PACKING ON BEARING HOUSING - TURBOCHARGERS 10912638 AND 53501-C- 130552, 8 poundefeet and secure with locking wire) (6) On turbocharger 10012698, se- fre compressor howsing to bear Ing housing with four cap screws (C) and two lock plates. Torque tighten cap screws to 17 pound feet and secure by bending tabs against screw heads,” Male cer (Gin tab ie against flat side of serew head, 44, Check Shaft and Turbine Wheel End Play Chock shaft and turbine wheel Refer to figure 51 ‘4, Position shim or shims (A) of qual thickness, ‘removed during disassembly, “over shaft and turbine wheel by Install clearance 10890180 (B) over shat. spacer - Se Apply film of grease to tick face and Stall lock ut anduigh‘on to atorgue of SO pound feet, Tighten lock nut in he same manmer a5 removed fig. 18) using 2 3/8-inch square ace Ket to hold opposite end of shalt and turbine heel. ‘TURBINE WHEEL END PLAY. CHECKING SHAFT ANDhnasing ur compressor back plate and position Inaeaioe.pouter against end ofthe shaft and turin whee fa Move shit and turbine wheel to extreme up aha down positions (E). Check total. shat ‘end play. Total end play should be between ‘.oo%- 16 0.008-Ineh onturbochargers 7748900 ‘And 10998279, and between 0, OO to 0,006-ineh Su turbochaagers| and S8801-C- 139552 bachavjer, ~The Ses of THE Taft olla Wwith washer andTlat Tit washer are the only eans of contro thrust tag ead gy -on tutochaygers”THH900 and Tobbsare The apacer sleeve thrust ring, Genet barca mr only mea orc Bing ne say oo turbockargers TOOT2008 SSTSIG01-C- RHR. Chec the ove pate fy tartare wort sac outer EStecouitnu tatine whe nt pay 45. Checking Compressor Wheel Back Clearance Check compressor Refer to inure 38 4. Check compressor whet back clearance WHEEL BACK CLEARANCE, should be between 0,020- to 0.022-inch, - Whe Clearance is not with specifications, add or Note, Shims are available n thicknesses of 00F.“0- 08 ae 0, O10-Tnch for torbo= sigere77a00ans T0WS7T0, 0.008, + nd U,O10-taeh for TuPDocTareers TORTESE ana BOS0I= C= 190557 b, Remove clearance checking spacer - 10899150 (B) alter correct clearance has been established, 46, Instelling Compressor Wheat Install the compressor wheel, Refer to Apply a light coat of Ibriplae to bore in coinpressor wheel (A). Remove all lebiplate from back face of compressor wheel, 1b Remove uit from vise and position shaft and turbine wheel of unit on support = 10890151 FIGURE 59, PRESSING COMPRESSOR WHEEL ON SHAFT AND TURBINE WHEEL(B) making cortain sg shat is centered on support fe Make certain proper thickness of shim (©) is installed aa directed in paragraph 48. 4. Press compressor wheel on shaft and turbine whee!" sing collar and. compressor wheel replacer--10800147 (D) until It bot- 47, Instoling Compressor Wheel Lock Nut Install compressor wheel lock nut. Refer to figure 60. Mount turbocharger in vise (A) Hold shatt and turbine wheel with an ight point 8 inch socket (B) to. prevent Gamage tothe square end of shaft fe. Apply @ film of grease to back face and threads of compressor whee! Tock nut 4. Insta compressor wheel lock ut using g/sinch socket wrench (C). Tighten Tock nut to-a torque of 80 pound-feet 48, Installing Compressor Extension Refer to paragraph 20 and reverse the se quence of instructions to instal the comprestor extension on turbocharger 10985278 ”1,1 9-2990.201-45 49. Installing Compressor Cover and Associated Parte igure 1 Coret position of eamprser set 4. Place clamp assembly over bearing hous ing 2. On turbocherger 10985279 only, install new gasket on compressor housing Mange and 44 new preformed packing on compressor ex- tension ©. On turbocharget 10912688 and 63601- (€-199562, install a new preformed packing in sroove in besring housing 4 Make certain the alinement mark on cover ales with mark on compreseor housing, Refer to figure 61 for correct positioning. of Position clamp assembly over compressor cover and hearing housing anges Caution: If lock mut is not lubricated, torque reading will be Incorrect and the lock rut could become loose in service and cause serious damage. J. Apply a film of srease to beck face and threads of clamp lock nut. Install lock nut and tighten to 4 torque of 10 pound- feet, 50. Installing Oil Outlet Cover and Oil Inlet Adapter (Rescinded)51. Tost Since the turbocharger performance depends up- fon engine performance, it cant be tested unless {is installed on an engine. Therefore, testing 4 dismounted turbocharger will consist only of ‘checking the shaft and turbine wheel for free Totation and making certain that shaft and tur bine wheel radial movement and end play does not exceed tolerances pointed out in paragraph 12: If the turbocharger passes these tests it shall, peitorm satisfactorily when installed on an en 2, ™ 9.2990-201-45 jon V. TEST AND ADJUSTMENT ‘Caution: Test stand operation of turbocharged engines without alr cleaner or shop filter sys- fem installed on the engine i prohibited. "The only adjustments necesary to the turbo- charges are adjustments made during overhaul 52. Adjustment ‘These adjustments are shaft and urine wheel end play (parm 48) and compressor whee! back learance (paea 48) Section VI. REPAIR AND REBUILD STANDARDS 53. General "The repair and rebuild standards included herein sive thy minimum, maximum, and key clest- fances of new or rebuilt parts, They also ive wear limite which indicate that point to which 1 part or parts may be worn before replacement, in order to receive maximum service with mini- tum replacement. ‘Normally, all parts. which Ihave not een orn boyond the dimensions show in the "Wear limits” column or damaged tm oon lb apo fo sve SEASTH Eh SA nn SHEA be ptr gr shal be ped nin grain he write ci Sw a cha pcm ete" Se one i eran) an ler Sasa’ ak tee Se a tte REE Srnec Se eh Po carve Se ie 54, Compressor Housing Assembly cnd Bearing ERM atee be ns ‘yi fe a0 55, Shaft and Turbine Wheel and Compressor Wheel °© 2, 1M 9.2990-201-45 58. Housing Assembly and Bearings & Soi dana ces ane SE Drain ars a fh Bio alee in hearing heing ROT Sc ang Flat Thrust Washer 41 or hast wher on sat nd abi: wi Thrust Collar Assembly| Sox Hol tinge deen lt Se trhine wheal ” Gute dameter oars washer 59. Bearing Thrust Washers and Thrust Ring 61. Spacer Sleeve 62. Thrust Bearing ¢ 2, 1M 9.2990.201-45 63. Compressor Back Plate, Flinger Sleeve, and Compressor Wheel Diam fark ate fe© 2, ™ 9-2990.201-45 mt te men smote ge bee 64. Bearing Thrust Washer 65. Bearing Housing Assembly and Bearings 0a Ould dma af sre bates, sas 1080 0m co Red croetcuiagla haine hosing ne. ggmeee eee St 66. Shaft and Turbine Wheel and Compressor Wht fli ete oan oie tes oe Me reer cee tea ee ° er te Ome Sp FICC hat and tne whl ince bearings ocmiaL to WOOL2, 9.2990.201-45, CHAPTER 5 INTRODUCTION Section 1. 67. Scope ‘4. Chapters 5 and 6 contain instructions for general support and depot maintenance of the Schwitzer Model 4 LE354 (10945184) (Cgs. 62 fund 69) and 4LE-456 (11641831) (figs 63.1 and 63.2) Turbochargers "The chapters contain descriptions and proed: ures for diessembly, inspection, repair and as- sembly. bh, The procedures covered in this change will GENERAL cover only those items peculiar to the Model 4 LEE series turbochargers, For complete mainte. ‘nance procedures, references will be made to applicable paragraphs and/or illustrations inthe Tasic manta, ‘The chapters, paragraphs, and ifustrations in this change fellow in succession to those in the basic manal. Refer to the bas manual for Special Tools and Equipment troubleshooting procedures, "© 2, 1m 9.2990-201-45,€ 2, 1M 9-2990.201-45 68. Difference Between Models ‘The following describes the differences between the Schwitzer Model 4 LE-354 and 4 LE-A56 turbochargers and the models covered in the asic manta, ‘The model 4 LE-354 turbocharger incor porates a wastegate asssembly to regulate maxi- ‘mum rpm of turbocharger onerstion, (6. ‘Tho model 4 LE-'56 turbocharger does not Section 11. 69. Description Refer to paragraph 4 and add paragraph b. (4) and (5) below: se @ waste gate nor does it require a nozele in ‘The turbine housing is duel chambered and was designed to provide proper airflow at all engine speods. © Engineering changos have been ineporpor- sted into the turbocharger to provide easier maintenance by eliminating pres fits, tii tion of fewer pars, and lighter weight DESCRIPTION AND DATA (4) The purpose of the wastegate mechan- iim is to prevent overspeeding of the turbo- charge rotating assembly.aust gases from the engine are circulated vugh the turbine housing mounted an the ‘ost manifold, ‘The velocity of the exhaust directed om the turbine wheel by nozzle in the turbine housing. The gap between nozzle ring vanes serves as the spoed eontral the unit Ifthe exhaust gas pressures build beyond a maximum point the gas velocity inerease through the nozsle ring and cause turbocharger to overspeed (5) The waste gate is an automotive type "e scated against an orifice in the turbine Sing passage, upstream from the nozzle ring. 2, M 9-2990-201-45 "The valve is held against its seat by a coil spring which is pre-loaded against the waste gate cove! ‘When execossive pressure builds up in the tit bine housing, sufficient to overcome the speir pressure against the valve, the valve opens allows the exhaust ges pressure to be reliew rectly into the discharge of the turbine hot ing, and thereby, prevents turbocharger ow speeding 70. Date Refer to paragraph 5.CHAPTER 6 REPAIR AND REBUILD Seetion | 71. General Refer to paragraph 16 72. Cleaning Before Disassembly Refer to paragraph 1 73. Removing Compressor Cover Rofer to paragraph 195, (1) and (2) and pare raph (1), below (8) Remove compressor eo with clamp (C, fig 15). Rem ering from beating housing {i 1 (B, fig. 38) fe and discard 64). \ fea = 74, Removing Nozzle Ring (Turbocharger 10945184) Lift nozzle ving from beating howsing following removal of compresor cover 4s DISASSEMBLY 75. Checking Shaft and Tur Wheel and Compressor Total Radial Movement Refer to paragraph 21 a, and b, except 6 (2) which is changed as follows (2) Check total wheel radial movement (B) in the same tanner as diveeted in para graph 12, 76. Removing Bearing Housing Assembly 4, Refer to Figure 21. Remove clamp nut (A) and postion clamp (B) to center of ‘bearing housing bang earefl not to move bearing hous Scribe alinement marks (C) on turbin, housing (D) and bearing housing (B) to insure correct positioning. during assembly Lift bearing housing (E) from turbine housing (D). Remove nozzle ring from bearing housing Cautions Immediately after removing the bearing housing assembly place it on the: com pressor wheel disassembly wupport, 10809153, ss shown in figure 25, to eliminate the posibil- ity of damaging compressor wheel blades. 77. Removing Compressor Wheel and Shaft, and Turbine Wheel «a, Refer to figure 65, Remove compressor wheel lock nut (A), and remove compressor Wheel (B)Refer to figure 66, Remove shaft and tur bine wheel (A) foam the hearing housing a sembly, aan em \° & 78. Removing Waste Gate Assembly (Turbocharger 10945184) «. Refer to figure 7. Secure waste gate cover with a siutable jack-clamp. Remove four 3/8— 16 x Tsinch cap serews (A) and two lock plates (B), attaching waste gate cover (C), to turbine housing (D)- Slowly" release. jack-lamp until ring tension ie relieved Warning: Cover is under spring pressure, hold cover securely during removal of cap serews, te © 2, ™M 9.2990-201-45 lease slowly to prevent injury to personnel and damage to assembly. 1, Refer to figure 68, Remove cover (H), gas ‘et (G), spring (F), spring cup (E), valve wide (D), fasket (B), and valve (C), fom turbine housing (A), Discard gaskets (B and G). 79. Removing Shaft and Turbine Wheel Piston Rings Refer to figure 69. Remove piston ring from shaft and turbine wheel using suitable ring ex ender Caution: Over expansion of piston ring. wi cause a permanent set or break the ring, After complete disassembly, to prevent blade damage, store the turbine wheel and compresior wheel In protected area 80. Removing Compressor Insert, ‘O-Ring and Flinger Sleeve 1. Snap Ring. Reler to figure 70. Using suit fable snap ing pliers, remove snap ring (A) ‘securing comprestor insert (C) in bearing hous ing (B) , Compressor Inert. Refer to figure 71. Re- ‘move compressor insert (A) from bearing hows ing (B) hy gently prying with two screwdrivers, © O-Ring and Flinger Sleeve, Refer to fg ture 72. Remove and diteard. O-ring (A). from compressor insert. Remove Mlinger sleve (C) front compressor insert (B 81. Removing Flinger Si Refer to figure 73. Remove cast iron piston ring (A) from finger sleve (B), using suitable ring cexpender. 82. Removing Oil Deflector, Thrust Ring, Spacer Sleeve, Thrust Bearing, and Thrust Ring Refer to figure 74. Remove oil deflector (E) thrust ring (B), spacer sleeve (D), thrust bent {ng (C), and thrust ring (B), fom heaving hous. ing, (A) ”Qurbad 6 1.14 9-2990-201-45 ad] 83. Removing Bearings and Oil Control Sleeve Reter to figure 75. Using snap ring pliers— 10935608 (ig. #2), remove outer snap rings (A) from recess in bearing housing. Remove cil control sleeve (D) and bearings (B). Re move inner snap rings (C) 84, Removing Name Plate Refer to ngure 76, Remove two self-tapping serews (A) and remove name plate (C) from bearing housing (B) s1, 9-2990-201-45 Section I. 85, Cleening Refer to paragraph 8, 86. Inspection and Repair «@. General. All parts must be thoroughly ex- amined and inspected to determine if they are suitable for rebuild of the assembly or if they rust be discarded and new parts substituted Some types of wear or damage may be de tected by visual Ingpection and other types Re: quire the use of suitable ‘measuring. tnsteu. ments, >. Compressor Cover, Refer to paragraph 38. ©. Compressor Wheel, Refer to paragraph 8. 4. Turbine Howsing. Refer to paragraph 88. @. Thrust Ring. (1) Inspect thrust rings for seored sure faces and distorted condition. Exam Ine thrust faces for scores or deep, scratches Chece thrust ing for die tortion as follows te May letters In (a) through (e) be low feter to gure 4. Components howe ‘gure 40 are tina andthe checking Pr (@) Place thrust ving (A) on a fat machined surface () Attempt to Ingert_an 0.002-ineh feeler gage (B) between thrust surface of thrust ring and fat ma chined surface. Gage should not enter between ring and fat surfice when ring is pressed lightly against the fat surface, (©) Measure the thrust ring with ‘micrometer. Thickness should not be ess than 0.092-inch and be parallel within 0.002-ineh (C) (2) The thrust rings must be replaced ‘when “found unservicesbe. Slight seratches and scores ean be removed by using crocus cloth J. Spacer Sleeve and Thrust Bearing. a CLEANING, INSPECTION, AND REPAIR (1) Inspect the thrust beating for seored for seratched surfaces, Check spacer sleeve bore diameter and length against limits specified in repair and rebuild standards. (par. 61). Check thrust bearing length between bear: ing surfaces against limite specified in repair and rebuild standards (par. 62), Replace spacer sleeve or thrust Dearing when not within specifi. tions. (2) Replace thrust bearing if there are deep scores or teratches, Slight seratches can be removed by singe roeus cloth, 9. Flinger Sleeve. Refer to paragraph 83% |, Bearings (2) Inspect shat sleevetype bearings for scratches and) worn surfaces, When bearings show evidence of wear, they rust be replaced. (2) Replace bearings if tin plate is worn off of Inside oF outside diameter 4 Bearing Housing and Compressor Insert (1) Inspect bearing housing and insert for cracks and damaged or scored bore. Replace housing and insert if damaged (2) Remove all raised metal on machined surfaces using a fine mill le. Do not attempt welding. a cracked housing. When cracked, replace housing i. Nozsle Ring. Refer to paragraph 881 , Shaft and Turbine Wheel. Refer to par- sugraph 83m. |. Turbine Housing. Refer to paragraph 88x. 1m. Waste Gate Assembly (1) Waste gate cover. Inspect waste gate cover for eracks, dents, of internal ‘damage that could eause spring wear for impair proper operation. Inspect over mounting surfaces for nicks oF burs, Remove minor dents and usesrocus cloth to remove burs. Replace cover if ‘racked, excesively bent, or otherwise damaged. (2) Spring. Inspect spring for resiliency and proper operation. (3) Spring cup. Inspect spring cup for excessive wear, cracks, distorted mating. sur face, and general condition. If wor, cracked, oF distorted, replace cup. (4) Valve guide and valve. Refer to fir- sure 77, Inspect valve stem outside diameter. ‘Check valve seat for smoothness and angle of face. Replace unserviceable valve. -n Clamp Assembly. Reler to paragraph 33. 0. Oil Deflector and Oil Control Sleve. Re: fer to paragraph 83s. Section I, 87. General Assembly Instructions, Paragraphs 89 through 99 are supplemented with illustra- tions, figures 77 and 78, that depict only thoee assembly operations which cannot be accom plished ‘by merely reversing the sequence of And procedures for disassembly, Where the as ‘sembly’ instructions, reference is made. to the pertinent. disassembly instructions, Where applicable, reference will be made to the basic ‘manual for appropriate assembly procedures. ‘The sequence of disassembly instructions (2), “(2), and” (3), for each paragraph should be performed in the reverse order ((3), (2), and “(1), to. accomplish the assembly, procedure Cleanliness During Assembly. Refer to paragraph 340, 88. Replacement Kits Refer to paragraph 35 and appendix T 89. Installing Bearings and Oil Control Sleeve [Refer to parsgraph 82 and reverse the sequence © 2, 9-2990.201-45, llews ‘ASSEMBLY of instructions to install the bearings and oil Control sleeve, Be certain beveled edge of snap Tings are toward center of beating howsing earings must seat against fat side of snap rings. Flange of oil control sleove must be sgainat bearing on turbine end of bearing, hos Ing. Fat side of outer anap rings must be against bearings 90. Installing Shaft and Turbine Wheel Piston Ring Refer to figure 32. Using shaft ring expander sleeve—10808148, install chrome piston ring on she 91. Installing Shaft and Turbine Wheel Refer to paragraph 77h and reverse the sequence of instuetions to install shaft and turbine whee] in bearing housing Caution: Use suitable ring compressor to allow piston ring to enter bearing housing 92. Installing Thrust Ring, Thrust Bearing, Spacer Sleeve, Thrust ing, and Oil Deflector Refer to paragraph 82 and reverse the te sa© 2, ™M 9.2990.201-45, one Severna | Pere 78 align int onl ‘quence of instructions to instal the thrust ring, thrust bearing, spacer sleeve, thrust ring and oil defector. 93. Installing Flinger Sleeve Piston Ring Refer to paragraph 81. Install eat iron piston ing on finger sie. using suitable piston ring expander. 94. Installing Flinger Sleeve, O-Ring, and Compressor Insert 4. Flinger Sleve and O-Ring, Reter to pars: raph 80c, and reverse the sequence. of in structions to install finger sleeve, and O-ring ‘on compressor insert, 4, Compressor Insert, Refer to. paragraph 806, and reverse the sequence of instructions to install compressor inset. © Shop Ring. Refer to paragraph 800 and reverse the sequence of instrwetions, to install snap ring. Beveled edge of snap ting ‘must be away from insert 95. Installing Compressor Wheel! Refer to pamrph 77a, and reverse the fequence of Intrctions 0" intal compreaor wheel and Tock mut. “Cont shalt threads and face of lock nut with graphite grease, Torque tighten to 1012 poundfeet, 96. Installing Waste Gate Assembly 4 Refer to paragraph 78, and reverse the ‘sequence of instructions to install new gaskets, ve, valve guide, spring cup, and spring >. Refer to paragraph 78a and reverse the sequence of instructions to install cover ‘using new lockplates, and cap screws, 97. Installing Nozzle Ring Install nozsle ring over turbine wheel on beer- ing housing. 98. Installing Bearing Housing Assembly a. Refer to figure 21. Place beating housing (B) in turbine housing (D) and line scribe marks (), 5, Position clamp (B) and install clamp nut (A). Apply. thin “coat of graphite grease to bearing housing flange. Tighten clamp nut to 10-pound-fet tongue 99. Installing Compressor Cover ‘Refer to paragraph 73 and reverse sequence of instructions to install compressor cover, Apply thin cont of graphite grease to bearing housing flange betore installation, Caution: Be sure slinement scribe marks ‘atch prior o tightening clamp nut to 10 pound. feet torqueAPPENDIX I-REFERENCES © 1, 1H 9-2990-201-45 airy Pubeations: Index of Army Motion Petre, Pl Stipe lide, and Phono Record Index of Blank Form Index of Graphle"Truning Ade and Devos Index of Supply Manuals Ondeance Core Index of Technical Mancaly, Tes Huletig, Supply Bling, Lubrication ‘Orders, and Modigenon Work Oratt 2 Forme DA Pam same DA Pam 310-3 DA Form 2008, Recommended Changes to DA Techseal Manual Pat Lists or Supply Mano, 8 ot 0 is Euipmert ieord Systems and Dcedures Ferm pertaining tothe Army Safety Progen ae prteribd It Supply Manual apne, Ausembiy w/Accnoron (2818-0801000) gine, Dice (Mlt-fods epindr, Miltary Model LDS-46-1 Engine, Dis! (Molten): Tarboupeeharged Pol Inject, Water Cold Terliger,Asserby (Continental ode! LDS-1-2) Step St, Mechanical Emergency Repair (110-0225) Ef acterte treet erleme a eal Ki, Genoral Mechanic's: Organisations! Maintenance, No.1 Common “eusii5e050) ‘ool Kit, Onguizatinnal Maintenance: No.2, Sappementa (440-154-0743) ‘Tool Kit Organization] Mainteance, Set A, Supplemental (180-754-065) ‘ool et, General Meckasic's Organizational Maintenance, Set No.2, Commis “PSN sis 766.50) 8 Repair and Rebs Enna, Atublyw Accesories (2815-90-7002) Engine; Dine! (Mai fol); eylindr, Miltary Mode LDS gine, Dice (MutSoe> Terbnupecharged, Fuel Injected, Water Cooled ‘epinderAnsembly (Continntl Model EDS-42-2) Mateviie ond for Cleaning, Preserving, Abreding, nd Coming, Ondance Matra; ad Related Material, Icing Cherie ‘ra 9.285-207 968 "TM 8815 210-48 1H 9-2n8-206.35P ‘ra o-2m0-200-007 SM 9-45180-A82 SU OL BIR-ASS SE 11I000-AOH SM St 5160-AIT Se 9-4. 5180-A29 5s51.1 9-2990-201-45 ' APPENDIX I ‘ GENERAL SUPPORT AND DEPOT MAINTENANCE. REPAIR PARTS AND SPECIAL TOOLS LIST Secion wRODUCTION ot 1. Scope Dh—Lhr—C— twa rar ea za tee Koy aati Sy Sa Spartan Depo aioane of Swe yg eh aie! en wer Model 4-456, 4D-454C, 4D-554 and 4LE ait os easehad bat are te be mone Fon secure RU ere 2. General, cared or coe a recelrenent for whieh ‘ The Roae Par and Speci Tose Lt a ee ! ‘divided into the following: sections (2) Maintenance Level, Column 1b. Ine 4 Introduetion Section I Aicates the lowest category of main- tenance authorized to. install the D. Repair Parte—Section ILA list of repair ae ees oes! parts authorized for the performance of main: tenance a the eneral sport and dept Tevel i in alphabetical sequence, o Organizational Maintenance, Special Tools—Seeton 11. A list of spe. ‘tet Supper Munem ‘ cial tls authorized for the performance at Seal Soot taintenance atthe general suport and depot (gy gecseenntieg sede Column 16. Ine F oo dicutes whether unserviceable items 4 Federal Stock Nunber ond Reference Should be returned for recovery oF amber tadesSecton TV" As of Peter ‘ivage Teme no coed re expend Sock Nombers flowed by veference nmbers She Recoverabity Codes are invascendingaiphirnineic sequence, rest ue peees reece ore ni an hum.“ — ota ra at ae 2. Explanation of Columns eeo8 ce at may ‘The following provide an explanation of 7 Ronag SMES “Rite eae coluins inthe faba hits setna rupee tape and 1. SMRATN AE tee temaiy oe 0. Source, Maintenance and Reeoverbtty Sats ceinal's Soa Cotes (Sith) atu rine (1) Source code, column 10. Indicates the U_—_Apiled ‘to ropa part pesifcly sled the selection status and soiree for Spent ntact ena me the lined item. Source code used Soir ae Sci we oe ee[Notes When no code in indicted inthe re Sucre the Pee em . Federal Stock Number, Colwnn 2. This column indicates the Federal Stock Number for the item, ‘. Description, Column &, This cohumn in dicates the Federal item name and any addi tlonal description of the item required. A part number of other reference number it followed by the applicable fivedigit Federal supply ‘code for manufecturers in parentheses, 4. Unit of lesue, Colum 4. This column in- dicates the units used as a basis for fssue, em, ea, pry ft, vd, te. 2. Quantity Incorporated in Unit Pack, Col ‘umn 5. This column indicates the actual quan: tity contained in the unit pack f. Quantity Incorporated in Unit, Column 6 ‘This column indicates the quantity of the Item used in the functional group, 9. $0-Day DS/GS Maintenance Allowances, Columns 7 and 8 (1) The allowance columns are divided Into ree aubealumna. Indicated. in ‘each sub-column, opposite the frst Appearance of each item, is the total uentty of items authorized for the imber of equipments supported Subsequent appearances of the same item will have no entry in the allow. ance column but will have in the de- Scription column a reference to the first appearance of the item. Ttems authorized for use as required but not for initial stockage are identified with an asterisk (*) in the alow. (2) The quantitative allowances for DS/ GS levels of maintenance will repre- Sent initial stockage for a 80-day pe- lod for the number of equipment “supported 1h. 1-Year Allowances Per 100 Bauipmenta/ Contingency Planing Purposes, Column ‘This column indicates opposite the frst re ‘quired for distribution and contingency plan hing purposes. The range of items indicates © 1, 1M 9.2990-201-45 fotel quantities of ll suthorized items re ‘wired to provide for adequate support of 100, fauipments for one year i Depot Maintevance Allowance Per 100 Equipments, Column 10, This column ind fates opposite the first appearance of each Hem the total quantity authorized for depot maintenance of 100 equipments. Subsequent appearances of the same. item will have no fentry in this column, but will have in the de- Scription column a reference to the frst ap- pearance of the item. Items authorized for use Dut not for initial stockage are identified with ‘an asterisk (*) Inthe allowance column, 4. Mlustration, Colum 11. This column is vided as follows (1) Figure Number, Column 110. Indi cates the figure number of the ilus- tration in which the item is shown, (2) Item Number, Column 178, Indicates ‘the eallout number ised to reference ‘the item inthe illustration, 4. Special Information ‘4 Identifeations of the usable on codes in- cluded in column 8 ofthis publestion are B Model 4-864 sa01-C-139652) © Mel 4150 Lease) . The basis of issue for authorized special tools, tert and support equipment is the mum- ber of end items of equipment supported and the number of maintenance personnel allo: cated to perform the required maintenance op- rations 5. How to Locate Repair Parts «4, When Federal Stock number or referinee umber ie unknown: (1) First, Using the table of contents, determine the assembly group, i ‘model number of turbocharger, with In which the repair part. belongs This is necessary’ sinee iMustrations are prepared by assembly groups for feach turbocharger and listings are Ativided Into the same groupe1, 1M 9-2990-201-48, 2) Sceond. Pind the ilustration covers ing the assembly group £0 which the repair part belongs, (8) Third, Identity the repair part of the w itustration and note the illustration figure and item momber of the reps part Fowrth, Using the repair parts list ing, fnd the assembly group to whieh the’ repair part belongs and. locate the ilustration figure and item ume Der noted on the illustration 4, When Federal stook members or refers ‘ence number is knot. (1) First. Using’ the index of Federal 2 Stock Numbers and Reference Num- bers, find the pertinent Federal stock Dumber of reference number. This in dex isin ascending alphasnamerie se ‘quence ‘erose-referenced to Ilustra: ton figure and item number. Second. Using the Repair Parts Lis ing, find the assembly group of the re Dir part and the ilastration figure And item number referenced in the Index of Feder 6. Abbreviations ce sept tnndedlameter incrporstd abt web ‘Fareed ‘monty Eeeverity 7. Federal Supply Codes for Manufacturers e908,€ 2, 1 9.2990.201-45, I worm[@ t #8 SONVNAINIVW 10430 GNY 14OddnS 1V¥IN3O ‘1YOddNS 193410 YOI SLuvd wIVaTE “U1 VOIDS= pets Ob egg Bia ine ye Figure 79. Turbocharger sembly 1069578 (4486) —expode view1, 1m 92990-20145 snen-a-s0es SDNVNAINIVW LOdid GNY LNOMdNS TWHINED ‘LHOdNS 193MIa HOS Slava BIVERE61, 1M 9-2990-201-45 cw0-mo-oes SDNVNAINIW 10490 ONY LHOddNS TWHRNIO * ‘BuOdans 193410 Hos Suva UIVERYgrad (ae we as sh on * ar1, 1M 9.2990-201-45 sor aus-oes swer-eo1-06se BIEIE ian neo = SONVNAINIVW 10diq GNV LModdnS TWHINGD ‘1WOgsNs LDaMIG YO! SLuvd IVER1 vies) (ores) LV i© 2, 1M 9-2990.201-43 AONVNAINIVW 10d30 GNV LOddNS TW¥INIO ‘1WOddNS 193WI0 AOS SLUVd wIVaTE© 2, ™ 9-2990.201-45 ATENASSY "aOUVHDOGUAL ~ s000 ES SONVNAINIVW 10430 GNV 1OddnS 1WBNIO ‘1WOddNS 193HIG YOs Siva wIvaTe€ 2, 1 9-2990-201-43 7 maepers we ae GD ] | x & ale lelee (eel ele] ele lelele F ial efile] e] #] a] 7 * Hye nae Aaa vel y ied a af — = | SONVNGINIVW 10d30 GNV LwOddNs TW¥BNID ‘1YOddNS 197 HOS Slav uIvaTYCc) ee a2, 1m 9.2990.201-45 (ers900) 24 sorts reo-oures ‘Sores on | exe r9 ct eax ore BE zm oR OR ro SDNVNGINIVW 10d GNV LuOddns Tv¥aNa9 ‘LuOdaNs ADFUI YO INAWAINDA LWOddNS GNY SIL ‘STOOL TIDRS “Ii UoIPaS61, 1M 9-2990-201-48, Section IV. INDEX—FEDERAL STOCK NUMBER AND REFERENCE NUMBER CROSS-REFERENCE TO FIGURE AND ITEM NUMBER eo. are 00 2 sates set se es ow. st2 0s a 2 dase foo 8B eons ie » ° s 3 ” B ee > Belen no eines sso 80 ” B-15608 onwrae mt mate = van wast isis. fn we 2 8 Bisose sr n€1, TM 9-2990-201-45 Saver eran Dae Bt Bt Soot ae Besaeseease© 1,1 9-2990-201-45 Thatteten Renorat Repa Cover a ox “Gang Reno Depot mnintenance wear init (ee Wear init) Baton ‘Bed pig, shaft and turbine whee Exhana fow Taapection Repair Finger sere (Sen Stee, figs) Forms ear, and repr por wear nits (See Wes limis) Hoasing, tearing Inept Toate introduction (See Scope) breton Maitnetion (Table 2) (ee Atvcatie, maintenance) ” ge 3588 = Bee 188,240 sage wai a 8Nomie ving (See Ring, sai) Operation art detention (See Appenie I) Pte Hage (See ings ela pon) ‘ening : Repair Reps pres BN seking spacing of Gating Helen Ramee ing, clr itn: ‘Geen ines Ange slaw: Remon! Remo ‘Shaft and earbine wie Gee eeepreseeees Saft ttre hee i Shi tere Inapecion 1, 1H 9-2990-201-48 m8 a = = ca % 7© 1, 1H 9-2990-201-45 ‘aning Ramer Roper Special ot table Spel tat Specitctons (See Dat) ‘rot clan (ee Calan, test) ‘hyustwather (See Water basing or At thrst) Teas and eqlpment, common Toa, speci ‘Ate dsasomiy (eating shaft and Carbine wheel radial movement Tale ‘Tortie wha (See Shaft and trie wha) (Se specie tem) Unatatactory supmentrepart Washer, basing throat Inspeton Repu Washer, fat chro Checking back earance Repair i y iy Bf ie = &By Order of the Seeretaty of the Army W.C. WESTMORELAND, General, United States Army, Ornicna Chief of Stag. KENNETH G. WICKHAM, Major General, United States Army, The Adjntant Genera. Distribution ‘To be distributed in accordance with DA Form 12-88, Direct and General Support require. ments for Truck, 244-Ton, Cargo, M85A2, M36; Repair Shop, M86: Tanker Ma9C, MBO, Tras or, M27, N62 M246 Van; 202A1, MIO9A1; Truck 5cTon, 6X5, Carvo, MB, MBB, Chass’ MOL, MOS, M130D, Dump, M51, Wrecker, 549,TM 9-2990-201.45 TURBOCHARGER, ENGINE, ASSEMBLY SEPTEMBER 1964