G3516 Generator Set ZBA00001-UP(SEBP3860 - 43) - Documentation Page 1 of 11

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Product: GENERATOR SET

Model: G3516 GENERATOR SET ZBA01078
Configuration: G3516 Generator Set ZBA00001-UP

Disassembly and Assembly

G3500 Engines
Media Number -SENR6419-14 Publication Date -01/03/2015 Date Updated -12/03/2015

i02500385

Turbocharger - Disassemble
SMCS - 1052-015

S/N - 4EK1-UP

S/N - 4WD1-UP

S/N - 5JD1-UP

S/N - 6JW1-UP

S/N - 7NJ1-UP

S/N - 8LD1-UP

S/N - 8PW1-UP

S/N - 9AW1-UP

S/N - 9TG1-UP

S/N - CPG1-UP

S/N - CPJ1-UP

S/N - CPS1-UP

S/N - CPY1-UP

S/N - CRC1-UP

S/N - CRN1-UP

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S/N - CSP1-UP

S/N - CSZ1-UP

S/N - E2C1-UP

S/N - E2E1-UP

S/N - E621-UP

S/N - E6N1-UP

S/N - E6R1-UP

S/N - E6W1-UP

S/N - E6Y1-UP

S/N - E6Z1-UP

S/N - E8A1-UP

S/N - E8C1-UP

S/N - TJ21-UP

S/N - TJ41-UP

S/N - TJ61-UP

S/N - TJ71-UP

S/N - WC21-UP

S/N - WC31-UP

S/N - WC61-UP

S/N - WC71-UP

S/N - WC81-UP

S/N - ZAZ1-UP

S/N - ZBA1-UP

Disassembly Procedure

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Table 1
Required Tools
Tool Part Number Part Description Qty
A 9S-6363 Holding Fixture 1
B 9S-6343 Fixture Assembly 1
C 1P-1853 Retaining Ring Pliers 1

Start By:

A. Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove".

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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Illustration 1 g01250400

Note: This procedure is a typical disassembly procedure for a turbocharger. Cartridge assembly
(3) is secured to compressor housing (1) and turbine housing (4) with clamp (2) and clamp (5).
All turbochargers will have the same basic components.

Illustration 2 g00593902

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Typical example

1. Place the turbocharger on Tooling (A). Mark the turbocharger housings for the proper
alignment during assembly.

2. Loosen clamp (2). Remove compressor housing (1) and clamp (2) .

Illustration 3 g00593906

Typical example

3. Loosen clamp (5) and remove cartridge assembly (3) from turbine housing (4) .

Illustration 4 g00593907

Typical example

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NOTICE

Do Not place a side force on the shaft when the nut is removed or
tightened. The shaft will bend and cause damage to the turbocharger.

4. Place the end of the turbine shaft in Tooling (B). Use a socket with a universal joint to remove
the nut that holds compressor wheel (6) .

Illustration 5 g00593908

Typical example

5. Use a suitable press to push the turbine shaft out of compressor wheel (6) and the cartridge
housing. Remove compressor wheel (6) .

Illustration 6 g00593915

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Typical example

6. Remove seal ring (8) and shroud (9) from turbine shaft (7) .

Illustration 7 g00593920

Typical example

Illustration 8 g00593918

Typical example

7. Bend the tabs of the locks away from bolts (10) and remove bolts (10) .

Note: Examine the position of the oil holes in the back plate assembly and the cartridge housing
for the assembly procedure.

8. Remove back plate assembly (11) .

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9. Remove spacer (12) from back plate assembly (11) .

Illustration 9 g00593922

Typical example

10. Remove seal rings (13) from spacer (12) .

Illustration 10 g00593923

Typical example

11. Remove thrust collar (14) and seal ring (15) .

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Illustration 11 g00593925

Typical example

12. Remove thrust bearing (16) .

Illustration 12 g00593962

Typical example

Note: Place an identification mark on the bearings if the bearings are reusable.

13. Remove bearing (17) and the washer from the cartridge housing.

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Illustration 13 g00593963

Typical example

14. Use Tooling (C) to remove retaining rings (18) and (19) .

Illustration 14 g00593965

Typical example

15. Remove bearing (20) and washer (21) .

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Illustration 15 g01257541

Typical example

16. Use Tooling (C) to remove the lower retaining ring (22) from the cartridge housing.

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