Turbo Chargers

1/23/24, 3:58 PM SIS 2.
Turbochargers (SENR2568-03)
SMCS -
T04B91, TW4B91 And TW4C01

PIP
-
202 1046
4
12: 01/2 666
/ 4
5
SEN 8:23+ 3
© 2 R256 03:00
024 8
Cat
erp
illa
rI nc.
Make reference to Analyzing Turbocharger Failure, FEG45138.
(1) End play for shaft (max) ... 0.10 mm (.004in)
(2) Thickness of thrust bearing (where thrust rings contact bearing) ... 5.36 ± 0.03 mm (.211 ± .001
in)
(3) Diameter of shaft (new) ... 10.152 to 10.160 mm (.3997 to .4000 in)
Bore in bearing (new) ... 10.185 to 10.196 mm (.4010 to .4014 in)
Maximum permissible clearance between bearing and shaft (worn) ... 0.05 mm (.002in)
(4) Maximum permissible gap of oil seal ring, measured in bore of housing ... 0.38 mm (.015 in)
(5) Install the compressor wheel (at room temperature) as follows:
https://sis2.cat.com/#/print-preview/service/9b4fa901-9f8a-4b6d-9210-2c49e679cb15 1/13
1/23/24, 3:58 PM SIS 2.0
a. Put compressor wheel on the shaft.
b. Put a small amount of clean engine oil on the threads.
c. Tighten the nut to 14 to 17 N·m (125 to 150 lb in).
d. Remove nut from shaft and apply 6V1541 Quick Cure Primer on the threads of the shaft and nut
followed by application of 9S3263 Retaining Compound.
e. Loosen nut and tighten again to 9 ± 2 N·m (80 ± 18 lb in) plus an additional 60 ± 5 degrees.
NOTICE
Do not bend or add stress to the shaft when nut is loosened or

tightened.
(6) Thickness of each thrust ring ... 2.553 ± 0.013 mm (.1005 ± .0005 in)
(7) Bore in housing (new) ... 15.799 to 15.806 mm (.6220 to .6223 in)
Outside diameter of the bearing (new) ... 15.702 to 15.715 mm (.6182 to .6187 in)
Maximum permissible clearance between bearing and bore in housing (worn) ... .15 mm (.006 in)
Torque for four nuts (put 5P3931 Anti-Seize Compound on threads) and bolts that hold turbocharger
to exhaust manifold ... 55 ± 5 N·m (40 ± 4 lb ft)
Torque the bolts that hold compressor housing to the center section ... 13 ± 1.7 N·m (115 ± 15 lb in)
Torque the bolts (put 5P3931 Anti-Seize Compound on threads) that hold turbine housing to the
center section ... 13 ± 1.7 N·m (115 ± 15 lb in)
Torque the bolts that hold the back plate ... 8.5 to 10.2 N·m (75 to 90 lb in)
NOTE: Put clean engine oil in the oil inlet of the turbocharger after assembly or before installation to
provide start up lubrication and/or storage protection.
TV61, TW61
1/23/24, 3:58 PM SIS 2.0
(1) End play for shaft (new) ... 0.08 to 0.25 mm (.003 to .010 in)
(2) Thickness of thrust bearing (where thrust rings contact bearing) ... 5.36 ± 0.03 (.211 ± .001 in)
Maximum permissible clearance between bearing and shaft (worn) ... 0.05 mm (.002in)
1/23/24, 3:58 PM SIS 2.0
NOTICE

tightened.
Maximum permissible clearance between bearing and bore in housing (worn) ... .15 mm (.006 in)
Torque the bolts that hold the back plate ... 8.5 to 10.2 N·m (75 to 90 lb in)
Install the band clamps to hold the cartridge to the compressor housing as follows:
a. Tighten clamps (put 5P3931 Anti-Seize Compound on threads) to ... 14 ± 1 N·m (125 ± 10 lb in)
b. Tap (hit) clamp lightly all around.
c. Tighten again to ... 14 ± 1 N·m (125 ± 10 lb in)
F302
1/23/24, 3:58 PM SIS 2.0
(1) End play for shaft (new) ... 0.114 ± 0.038 mm (.0045 ± .0015 in)
Maximum permissible end play (worn) ... 0.20 mm (.008 in)
in)
Maximum permissible clearance between bearing and shaft (worn) ... 0.08 mm (.003 in)

1/23/24, 3:58 PM SIS 2.0
e. Loosen nut and tighten again to 30 ± 3 N·m (265 ± 27 lb in)
NOTICE

tightened.
(7) Bore in housing (new) ... 22.255 to 22.268 mm (.8762 ± .8767 in)
Maximum permissible clearance between bearing and bore in housing (worn) ... 0.15 mm (.006 in)
b. Tap (hit clamp lightly all around.
3LM
1/23/24, 3:58 PM SIS 2.0
(2) Thickness of thrust bearing (where thrust rings contact bearing) ... 2.72 to 2.74 mm (.107 to .108
in)
1/23/24, 3:58 PM SIS 2.0
e. Loosen nut and tighten again to 30 ± 3 N·m (265 ± 27 lb in)
NOTICE

tightened.
(6) Thickness of each thrust ring ... 2.72 to 2.74 mm (.107 ± .108 in)
Torque the bolts that hold compressor housing to the center section ... 6.8 N·m (60 lb in)
Torque the bolts (put 5P3931 Anti-Seize Compound on threads) that hold turbine housing to the
center section ... 15 to 17 N·m (132 to 150 lb in)
S3B
1/23/24, 3:58 PM SIS 2.0
PIP
202 -1046
12: 4 / 0 4 666
5 1 / 2
SEN :23+ 3
8
© 2 R256 03:00
024 8
Cat
erp
illa
rI nc.
in)

1/23/24, 3:58 PM SIS 2.0
NOTICE

tightened.
S4D
1/23/24, 3:58 PM SIS 2.0
in)
(3) Diameter of shaft (new) ... 15.997 mm to 16.005 mm (.6298 to .6301 in)
Bore in the bearing (new) ... 16.035 to 16.043 mm (.6313 to .6316 in)

1/23/24, 3:58 PM SIS 2.0
e. Loosen nut and tighten again to 4 ± 2 N·m (35 ± 18 lb in) plus an additional 90 ± 5 degree
rotation.
NOTICE

tightened.
Tighten both band clamps (that hold the compressor and turbine housings to the cartridge group)
with the procedure that follows:
a. Tighten clamp (put 5P3931 Anti-Seize Compound on threads) to ... 14 ± 1 N·m (125 ± 10 lb in)
NOTICE
Do not over tighten the clamps.
Torque for four nuts (put 5P3931 Anti-Seize Compound on threads) and bolts that hold the
turbocharger to the exhaust manifold ... 55 ± 5 N·m (40 ± 4 lb ft)
PIP-10464666
2024/01/23
12:58:16+03:00
1/23/24, 3:58 PM SIS 2.0
SENR25680022
© 2024 Caterpillar Inc.

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1/23/24, 3:58 PM SIS 2.

T04B91, TW4B91 And TW4C01

Make reference to Analyzing Turbocharger Failure, FEG45138.

(1) End play for shaft (max) ... 0.10 mm (.004in)

Bore in bearing (new) ... 10.185 to 10.196 mm (.4010 to .4014 in)

(5) Install the compressor wheel (at room temperature) as follows:

a. Put compressor wheel on the shaft.

b. Put a small amount of clean engine oil on the threads.

c. Tighten the nut to 14 to 17 N·m (125 to 150 lb in).

Do not bend or add stress to the shaft when nut is loosened or

Make reference to Analyzing Turbocharger Failure, FEG45138.

Bore in bearing (new) ... 15.921 to 15.931 mm (.6268 to .6272 in)

(5) Install the compressor wheel (at room temperature) as follows:

a. Put compressor wheel on the shaft.

b. Put a small amount of clean engine oil on the threads.

c. Tighten the nut to 14 to 17 N·m (125 to 150 lb in).

Do not bend or add stress to the shaft when nut is loosened or

b. Tap (hit) clamp lightly all around.

c. Tighten again to ... 14 ± 1 N·m (125 ± 10 lb in)

Make reference to Analyzing Turbocharger Failure, FEG45138.

Maximum permissible end play (worn) ... 0.20 mm (.008 in)

Bore in bearing (new) ... 14.293 to 14.300 mm (.5627 to .5630 in)

(5) Install the compressor wheel (at room temperature) as follows:

a. Put compressor wheel on the shaft.

b. Put a small amount of clean engine oil on the threads.

c. Tighten the nut to 14 to 17 N·m (125 to 150 lb in).

e. Loosen nut and tighten again to 30 ± 3 N·m (265 ± 27 lb in)

Do not bend or add stress to the shaft when nut is loosened or

b. Tap (hit clamp lightly all around.

c. Tighten again to ... 14 ± 1 N·m (125 ± 10 lb in)

Make reference to Analyzing Turbocharger Failure, FEG45138.

Maximum permissible end play (worn) ... 0.20 mm (.008 in)

Bore in bearing (new) ... 14.293 to 14.300 mm (.5627 to .5630 in)

(5) Install the compressor wheel (at room temperature) as follows:

a. Put compressor wheel on the shaft.

b. Put a small amount of clean engine oil on the threads.

c. Tighten the nut to 14 to 17 N·m (125 to 150 lb in).

e. Loosen nut and tighten again to 30 ± 3 N·m (265 ± 27 lb in)

Do not bend or add stress to the shaft when nut is loosened or

Maximum permissible end play (worn) ... 0.20 mm (.008 in)

Bore in bearing (new) ... 12.741 to 12.748 mm (.5016 to .5019 in)

(5) Install the compressor wheel (at room temperature) as follows:

a. Put compressor wheel on the shaft.

b. Put a small amount of clean engine oil on the threads.

c. Tighten the nut to 14 to 17 N·m (125 to 150 lb in).

Do not bend or add stress to the shaft when nut is loosened or

b. Tap (hit) clamp lightly all around.

c. Tighten again to ... 14 ± 1 N·m (125 ± 10 lb in)

Maximum permissible end play (worn) ... 0.20 mm (.008 in)

(5) Install the compressor wheel (at room temperature) as follows:

a. Put compressor wheel on the shaft.

b. Put a small amount of clean engine oil on the threads.

c. Tighten the nut to 14 to 17 N·m (125 to 150 lb in).

Do not bend or add stress to the shaft when nut is loosened or

b. Tap (hit) clamp lightly all around.

c. Tighten again to ... 14 ± 1 N·m (125 ± 10 lb in)

Do not over tighten the clamps.

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