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EXHAUST GAS TURBOCHARGER

R%S
TYPE RH183/183L/203
(Version : Y )

lWiMIJ-#R%4' 71Jj3' n92' 8'


( t 5 7 ~ - - b 4 7 ? 1>Y)
Bearing housing with foot
(Semi-f loat bearing)

aaRMY14
Instruct ions
for operation and maintenance

6J~l~##4SiE%#8Wk

Ishikawajima-Harima Heavy Industries Co., Ltd.

TOKYO JAPAN
RH183FSYA- R3
TSU 9 - $ 9 2 5 - A X TSU Turbo Systems United
J-f-f 5-Y FR3ea Co., Ltd.

Tokyo
East Japan Service Dept.
Arca Central Building 18F 2-1, Kinshi
1-chome, Sumida-ku, Tokyo 130-0013,
JAPAN
TEL 03-5611-5983-5986 TEL +81-(0)3-5611-5983-5986
03-5950-0491 (24hrs) +81-(013-5950-0491(24hrs)
FAX 03-5611-5997 FAX +81-(0)3-5611-5997

East Japan Service Station


22- 1, Honjo 1-chome, Sumida-ku,
Tokyo 130-0004, JAPAN
TEL 03-5619-5021 TEL +81-(013-5619-5021
FAX 03-5619-5022 FAX +81-(0)3-5619-5022

Kobe
West Japan Service Dept.
West Japan Service Station
3-2, Wakihamakaigandori 2-chome,
Chuo-ku, Kobe-shi, Hyogo 651-0073,
JAPAN
(fi~*Y-cx%) (West Japan Service Dept.)
TEL 078-200-3092 TEL +81-(0)78-200-3092
FAX 078-200-3096 FAX +81-(0)78-200-3096

(%EI*Y--Exx7--93 (West Japan Service Station)


TEL 078-200-3093 TEL +81-(0)78-200-3093
FAX 078-200-3096 FAX +81-(0)78-200-3096

-+*~%Fr Imabari Office


f 799-1506 %%?E+%vdmSfF$;f 3-9-36-303,Higashimura, Imabari-shi,
3-9-36-303 Ehime 799-1506, JAPAN
TEL 0898-48-8750 TEL +81-(0)898-48-8750
FAX 0898-48-8751 FAX +8 1-(0)898-48-8751

Kyushu Service Station


1418, Aza-Daima, Ueki, Suemachi,
Kasuya-gun, Fukuoka 811-2112,
JAPAN
TEL 092-931-2051 TEL +81-(0)92-931-2051
FAX 092-931-2052 FAX +81-(0)92-931-2052
& k7$3 FOREWORD

To make full utilization of the IHI Exhaust-Gas


IHI $IF% 9 - r >;M$fi& (LX T;j&$E& 2 tag L 3
turbocharger (hereinafter briefly called
-i-)
D & ~ ~ E & W ? I ~ E ~ F $ -rG<
I&KT IT,
"turbocharger"), it is important to comply with
&$$S~?I. TL\~&+~!Z.)~-,?A,fgi,Tfi$&, .:''?&&$Lg
the procedures for operation and maintenance
J@ <
5'j?g3,!jC9T 2 7):,g,-E:TTc
a s well a s instructions contained in this
instruction manual.
Operate the turbocharger after reading through
this instruction manual.
CAUTION

1.Order and inquiry

(1)When ordering the parts, clearly indicate the


following symbols in your order sheet.

Type RH ...
Serial-No, As stamped on the rating
Specification plate of turbocharger
(Refer to Fig. l,sect.2-2)

P a r t number
and designation
Quantity I As per Fig.2bect.2-3) and
parts list(sect.2-2)

(2)Address your order and inquiry to our


agencies and service offices or engine
builder's service stations.

2.Exemptions of liability
I n respect of accidents during the guarantee
period that are recognized a s being clearly
attributable to IHI's design or manufacture,
IHI will make repairs free of charge, but IHI
will assume no responsibility even during the
guarantee period for the following accidents.

(1)Accidents due to the use contrary to the


instructions contained in this manual
(2)Accidents due to a neglect of periodic
replacement of wearing parts
(3)Accidents due to the use of parts other than
IHI genuine parts
(4)Accidents due to the use i n excess of the
rated capacity

3.Communication
Regarding the doubts about this instruction
manual, obscure points therein, special cases
not stated therein or any disorder, etc., please
contact the engine manufacturer or the
nearest IHI business office.

4. Caution

(1)Do not touch the turbocharger in operation,


because the turbocharger is in a high
temperature and high-speed condition.
(2)Dismantle or remove the turbocharger after
getting cold.
Content s

1.Instructions on safety and hazards


1.1 Basic safety instructions
1.2 Special safety instructions
1.3 Hazards and hazard protection

2. Construction and function


2 . 1 Construction of the turbocharger
2.2 Parts list
2.3 Structural drawing

3.0peration
3.1 Lubricating oil
3.2 Operation
3.3 Inspection and maintenance

4.Maintenance
4.1 Cleaning
4.2 Tools
4.3 Weights
4.4 Disassembling the turbocharger
4.5 Reassembling the turbocharger

5.Faults
5.1 Symptoms of faults and possible causes

6.Cleaning the compressor in service

Service offices
1. Instruction on safety and hazards

1.1 Basic safety instructions

The following symbols and terms are used in


this operation manual for safety instructions;

Warning!
Serious injury or fatal accident may result if
the working and operation instructions
marked with this symbol are not, it only partly,
observed.

Warning signs must be strictly observed.

/i\ Caution!
Serious damage to the machine or to other
property may result if the working and
operation instructions marked with this
symbol are not, or only partly, observed.

Caution signs must be observed to the letter.

IW Note
Work can be carried out more efficiently and
simply when work and operation instructions
marked with this symbol are observed.

Notes help to simplify your work.


1.2 Special safety instruction

The instructions here are designed to


ensure your safety and to promote safe
handling of the turbocharger and its
operating materials.

These safety instructions must be observed


when working on or operating the
turbocharger.

Work on a turbocharger only in a stable


physical and mental condition.

Wear protective clothing (helmet, ear


protection, protective glasses, protective
suit, gloves, protective shoes).

Attach individual parts and large


component modules carefully to suitable
lifting devices which are in technically
prefect condition and which possess
adequate load-bearing capacity.

Do not stand under suspended loads.

For overhead assembly work use the steps


and work platforms provided for this
purpose.

Do not use machine parts a s steps.

If welding work is to be carried out above


the turbocharger, the air filter must be
covered to prevent damage to the filter mat.

1.2.1 Safety when connecting

Work only on those connections for which


you are qualified.

1.2.2 Safety when commissioning a n d


during operation

Before starting to work make a visual


inspection of the working area

Remove obstacles and any other objects


lying around from the work area.

Before commissioning check the


turbocharger for damage or leaks.

Refrain from any actlvlty which could


Impair safety a t the turbocharger.
12 B~BH'JEES <
L I3972 < 21 5 1 I 11: 1 lqC3,.
Inspect the turbocharger approx. every 12
hours or a t least once a day for visible
external damage and defects.

Report immediately any damage or changes


in operation performance to the person 1
department responsible.

In the event of damage, shut down the


turbocharger immediately and secure it
against unintended or unauthorized
interference.

Do not stay by side of the turbocharger.


Can burn and cause personal injury by
fragmentation.

Do not touch the surface of turbine housing,


compressor housing, bearing housing, feet
and blanking device. Serious burning due
to high temperature.

1.2.3 Safety when cleaning


? % # ~ ~ z ? E R ~ H ~ + j % j ~ W9
I ] Q5l ~&R ~ ~ ~ &
t1&5 cz. i@$~+%l~lU)a>KE$IEL-C< 7Zf Before cleaning, protect the floor against
unintended leaks of oil and operating
Ljo
materials.

Wear protective clothing (oil - and petrol -


resistant gloves, protective suit, eye
protection, knee protection, foot protection).

Handle operation materials and detergents


with utmost caution.

When handling solvents, protective


clothing must be worn. Avoid contact with
the skin, inhalation and penetration of
clothes.

Water splash from dosing vessel for


compressor washing.
1.2.4 Safety when disassembling and
assembling

Inform operating personnel accordingly


before starting any special or maintenance
work.

As precaution, place a receptacle for


leaking oil under the turbocharger.

When disassembling, secure the rotol-


against turning.

Ensure that absorbent material is available


z ~ d & f z ~ @ ~ $ Q ~ t ! ~dr -54 le.
~ 6 3 f i ~ ~ ~ ~
to soak up any spilled fluids.
%U%$d%TiBLT< E S t j o
Ensure t h a t operation and process
materials are drained, collected and
disposed of in a safe and environmentally
compatible manner.

Ensure t h a t the prescribed, adjustment,


maintenance and inspection work is carried
out a t the appropriate intervals.

Observe instructions for replacement of


parts.

Retighten screwed connections in


accordance with the respective regulations.

Do not touch the surface of locking device,


may cause burn.

1.2.5 Safety when shutting down

Secure the rotor against turning.

Clean the turbocharger before mothballing.

Wear protective clothing during


mothballing the turbocharger.

Keep the work area clean and free of oil


and operating materials.

Remove any obstacles laying al-ound on the


floor.
1.3 Hazards and Hazard protection

Hazards may arise during operation of,


and work on, the turbocharger:

from the turbocharger and its accessories

from the operating materials used

from failure to observe safety instructions

from inadequate maintenance and


inspection work

1.3.1 Mechanical influences

Physical injury

A Warning!
~a,k5$LkP~~%%3ftLB
. JS.L f c Unconsciousness and injury due to:
L) Tmieinch ij sq0 Crushing, shearing, cutting, winding,
R L 9 S S h 6 . l&S3#L6. fragmentation, drawing in, knocking,
tJJBiSh6. % $ i A 3 h 6 . stabbing, rubbing, loss of liquids under
@J+l=k blthc. 3lh\hb, S ~ l t b . high pressure, under burnt, high
%4SllSQ, LT6. i%EATcr)@i3. temperature, slipping, tripping falling.
A.

E ~ I = ~ . ~ A MB, , am, Causes


sharp edges, pointed parts

crush, shear and winding areas

fragmentation of parts

fracture or rupture of parts due to


overload

elastic elements (e.g. springs), liquids


and gases under pressure or in a
vacuum

slippery, oily work area, obstacles on


the floor
Protection measures
Wear Leather protective gloves

Wear close-fitting protective clothing

Tie up long hair a n d bearings, wear


hair protection

Wear face a n d eye protection

Wear protective shoes

Keep floor, equipment and the


turbocharger clean

Ensure t h e availability of oil -


absorbing materials.

Eliminate leaks

1.3.2 Operation and process materials

This includes all substances such a s oil,


grease, coolant, detergents a n d solvents,
acids a n d other hazardous substances.

Physical injury and damage to property

Warning!
Allergies, skin disease, unconsciousness,
poisoning or nausea after inhalation.
Injury by scalding and burning of the skin.
Burning by vapors or contact with acids
or alkalis.

Caution!
Environmental pollution due to leakage of
operation a n d process materials a n d
penetration into soil a n d water.

Causes
Inhalation of toxic gases, smoke a n d
vapors

Skin contact with aggressive fluids

Clothing wet or soaked with hazardous


substance

Spilling a n d tipping o v c ~of vessels


with operation materials
Leakage

Tanks and collectors which are not gas


- tight and which do not comply with
the regulations on hazardous
substance

Burning cigarettes or naked flame in


the proximity of operation materials

Protection measures
Utmost caution when handling
operation and process materials.

Protective clothing must be worn (oil -


proof, solvent - proof and acid - proof
gloves, impermeable protective
clothing, and respiratory protection).

Avoid skin contact and inhalation.

Ensure that the workroom is properly


ventilated.

Observe the hazard indications on the


containers for operation and process
materials.

Immediately after use, seal the


hazardous substance container tight.

Used operation materials must be


collected safely in accordance with the
legal provisions, stored separately in
suitable containers a s prescribed, and
disposed of as special waste in a n
environmentally compatible manner.

Ensure that containers with new / used


operation materials are sealed tight.

In the event of leaks or spills


immediately apply a suitable
absorbent material and dispose of this
in a n environmentally compatible
manner as special waste.
1.3.3 @is 1.3.3 Noise

iW&l%J@% Physical injury

Warning!

Loss of hearing, deafness impairments of


health such a s loss of balance or of
consciousness, cardiac and circulatory
disturbances.

Causes
Machine noise level in excess of
90dB(A)
Protective measures
Wear ear protection
1.3.3 Noise

Physical injury

A warning!

Loss of hearing, deafness impairments of


health such a s loss of balance or of
consciousness, cardiac and circulatory
disturbances.

Causes
Machine noise level in excess of
SO~B(A)
Protective measures
Wear ear protection
2. Construction and function

2.1 Construction of the turbocharger


The RH1831203
type turbocharger consists essentially of a
mixed flow turbine and a radial flow
compressor assembled a s a single unit.

(1) Turbine
The exhaust gas from the diesel engine flows
through the turbine housing (4001) to the
turbine wheel and provides the rotating
torque to the turbine shaft (1001).
The exhaust gas flows through the exhaust
pipe to the atmosphere.
Seal ring 1009) and heat shield (5005) are
provided so that gas may not adversely affect
the bearings.

(2) Compressor
The compressor wheel (2001) fitted to the
turbine shaft (1001) receives the rotating
torque, induces air through the silencer
(10001), and delivers it to the cylinders after
compression.
Seal plate(6001) and seal ring(1010) is
provided so that air and oil may not leak.

(3) Bearing
A. Thrust bearing(7002)
Since thrust force is constantly applied to
the turbine shaft (1001), the thrust bearing
(7002) is provided to prevent move of the
shaft due to thrust force.

B. Journal bearing
A semi-floating type is employed.
A conventional floating bearing rotates, but
semi-float bearing (7001) don't rotate.
2.2 3 3 n"n 2.2 Parts list Table.1 Parts I
3L% 83 k;
1)eslgnation
Parts No
1001 Turbine shaft
1002 T h r u s t collar
1004 Distance piece
1006 Sealing bush
1008 Shaft end hexagon n u t
1009 Seal ring (Turbine side)
1010 Seal ring (Conpressor side)
200 1 Compressor wheel
3001 Compressor housing
3003 Hexagon head bolt M10X 35
3006 Spring lock washer 10
3007 Cross-recessed head screw M8 X 25
3010 Plug GI318
3011 Pucking 16.5126
3021 Hexagon head bolt M I 0 X 95
400 1 Turbine housing
-1002 Turbine side clamp
4003 Hexagon head bolt M I 2 X 20
4006 S t u d bolt M16 x 55
4008 Hexagon n u t M16
5001 Bearing housing
5002 S n a p ring
5003 Hexagon head bolt M10 X 45
5004 Spring lock washer 10
5005 H e a t shield
5006 0 ring G I 3 5
6001 Seal plate
7001 Semi-Float bearing
7002 Thrust bearing
800 1 Diffuser
10001 Silencer
10002 Air filter
10003 Hexagon head bolt M10 X 3 5
10004 Spring lock washer 10
11006 Turbine side foot
11008 Clamp
Clampimg spring
Hexagon head bolt M8 X 16
Spring lock washer 8

EXHAUST GAS
ifi %4% Jf$ k t IHI TURBOCHARGER

j ~ ~ ~ #4%. 4 ~ \, TYPE RH
Brsiiits :-+lb
SPEC.

T H Maximun allou~ableSpeed
\ SERIAL NO.
j@g;&~,g;f~$$+~$~& and maximun allo\vance gas
$;& LK \ Nmax s1 Tmax 9= temperature
%,<5;'rF;jJ X(,%&
I, IHI TOKYO JAPAN il'hl (
\ q2,;rnfL49
I

{YJ 1x1 1. j& ${; 24 +h Fig.1 Rating plate Special design feat11l.r
M42. RH183/203%&$6%%3Q
F i g . 2 . Structual Drawing for t y p e of RH183/203
I
REF. Orminc No. REV.
IH I TURBOCHARGER ENGINEERING DEPARTMENT H4Z15459
15
3. Operation
3.1 Lubricating oil
The RH turbocharger can be connected to
the lubricating oil system of the diesel
engine. Therefore the lubricating oil must
have the quality mentioned in the engine
builder's recommendation.

3.1.1 Interval for oil changes and


replacement of filter
The oil must be changed according to the
engine builder's recommendation.
Ensure t h a t the fine filter preceding the
turbocharger is kept clean, and the filter
element must be cleaned or replaced
periodically.

3.2 Operation
For new or overhauled turbocharger, note
the following points.

3.2.1 Before taking into service


All pipes have to be fixed in a way that
there are no forces t h a t could deform the
casing.
Any deformations on the casing can affect
the bearings.

All lubricating oil pipes must be cleaned


thoroughly before taking into service.

Before starting the engine, always operate


the pre-lubrication system.
The oil pressure is according to the engine
builder's recommendation.

3.2.2 When first taking into service


Check all gas, air, and oil pipe connections
for tightness.
3.3 Inspection and maintenance
Check up conditions a n d contamination of
the turbocharger periodically.
Intervals of inspection may be changed
according to operating conditions, following
intervals are recommended.

3.3.1 Periodical inspection and maintenance


r I I I I
Application Inspection interval
Inspection Marine engine Every Every Every Every
points & generator 400 hrs 1200 hrs 2400 h r s 4800 hrs
Checking of clamped parts for tightness 0
Rotating condition of turbine shaft 0
Checking of clearance of turbine shaft 0
Disassembling, cleaning and inspection I
Cleaning and inspection of oil filter I n accordance with instruction manual of the
.-
+
cd
.2 E
'r a,
Engine oil change engine
P cJ
5 m
Inspection of oil pipe system 0
Inspection of intake and exhaust pipe
other 0
system
Compressor Impeller

Turbine shaft

Compressor housing

Do not push the blades of


compressor impeller
m

P Photo 3
3.3.2. ,6@Ol$d>b 3.3.2 The points of Inspection

--g z z%pd@:
3.3.2.1
-.?
400 %$i#f;f3a>k% 3.3.2.1 Every 400 hours: Check all fixing bolts
Note
This check is to prevent a leakage of exhaust gas
%3UlTf;)Lt-,f ~ Y ~ - U I ~ & I S ~ ~ ~ ~ ~ - O ~ ~ F Z
and lubrication oil due to looseness of bolt and
%'XjEhBUjHiB;QjEhaflAko nut.

3.3.2.2 1200 @~B?$S:9 - E ' > n - 9 a m $ 3.3.2.2 Every 1200 hours: Check the
6 % (Photo 1 ) rotation
-- of rotor
(Photo 1)

9 - f > ~ - 9 ~ ~ 5lB\k\L)
~ L ~h<G<@<lEI
.
A Caution Check if the rotor rotates smoothly by hand. If the
~ I ~ E % T $ ~ rotor rotates heavily or touching noise occurs, the '
turbocharger must be dismantled for inspection.
~ < ~ a ~ t + t g f i ~ t a (Refer
~ 6to the
~ Sect.4.1,
~ I ~ ~ ~ T ~ a
4.4 and 4.5.)
T T 0 (4.1, 4.4, 4.5 I R g
1
P~l,-C<t~$L\o

3.3.2.3 Every 4800 hours: Check the


clearance of rotor
1 )9-E'>~-909'!77>XB%/Et~!~IZ$~
) H~~ to measure clearances
~~h~~!11)P7>Xa)~t~!Il @Axial clearance
Photo 2
Photo 2
: 9-e'>u-9E9-~>il~ll= 3-+?#'To
. y,f+)l/'i'-:,(J)o&~tn- .,,, : Push turbine shaft to turbine side end by hand.
.xi~?-6o :Set dial gauge to zero.
Photo 3
Photo 3
: I>?I/*YY~!~/. I-++RFo : Push turbine shaft to compressor side by hand.
: 94+)LY--5ai$ES%&4~6~ : Record the reading on dial gauge.
: Ca>i$h<$h%r;;l9II77>Xtrf~6~ :This reading is axial clearance.

l ~ x i aclearance
l 1 0.08 - 0.15 (rnrn)

A caution
There are some cases where axial clearance is less
the low limits Max. 0.02mm owing to oil film etc.

QRadial clearance
~~~~%r;;l9~!Ps>Xa;t~W~l
: g,f+)LY-5gI>Y l,Yv4>&7%?%3- : Set the dial gauge pointer at the top end of
compressor impeller and set dial gauge to Zero.
*Yt-f&, 0,6Ei2Z$ao Photo 4
Photo 4
: Push the turbine shaft upwards at compressor side
: 9-E'>u-9aI>Yb~Yvil~lEkZnl=#'
by hand.
3-0 :Record the reading on dial gauge.
: ~'I'+)LY-~OI~E$~%&RX~~
Photo 5
Photo 5
:Push the turbine shaft downwards at compressor
:~ > Y I / ~ Y v ~ ~ l E T z m l =Tlf~~ side by hand.
: g+f+)LY-5miEEz%&4~6~
: Record the reading on dial gauge.
: kzmtrTznae$tht*f3%m9l)77>X
:The total movement from upper position to lower
kG6 position means radial clearance

Allowable radial clearance is shown as follow

Initial clearance allowable


I Radial clearance 0.45 - 0.6O(rnrn) 0.80(mm)
= g~
Ti$ if Repeat
' 31)P~>xEt~W~ll;t;3~~B~~l)gL~;ie~~,
Note
the measurement at least 3 times, and check
the average recording is within permissible range in
6 below Table 1.3.2.In case of overhaul or inspection,

When measured clearances are over the high limits


M ~ ' ! S ~ ~ Z S U ~ ~ C _ ~ S I G B ?%L
~ - Cor
L' ~ %the
when ~ .scoring or excessive wear is observed
<lAh'71J>3'l=Q+ARkfRGhbY%I=It.A? on the bearing surfaces. replace thrust bearing
~ b ~ ' 7 ~ ) > 3 ' ( 7 0 0 2 ) & k ~ . t ! ~ 7 ~ - b * \ * \ ? ~ ) > 3 ~ ( 7(7002)
0 0 1 ) ~and semi-float bearing (7001).
3~LTTSL'o

Xb~'?1J)3'(7002)BU:+t7~ab~"31J > 3 3 For safety operation, replacement of thrust bearing


12. k ~ @ % ~ ? t i _ Z L \ t d - ' L \ % ~ ~ & ~ . f 7 ' d ~ $ % ~ (7002) and semi-float bearing (7001) every 2 years
%$#~t~& Z El =$ Z.% B B ~ I = M ~ G J ~ ~ * E ~ DisZrecommended independent of operation hours or
@%%WBLb+o clearance measurement

A Caution
%%';a ( L O ) D a A L ) U I ; ~ : ~ L X % I = T = S ; E A % Cover Lub. oil inlet and outlet with rag to avoid dust
13fiL\T<t5a.\o invasion.
z l > ~ l / . 2 Y d > ~ 7 I $ ~ l l / ~ $RXl))RL\fY
$~$, Compressor impeller is made of AL-alloy. Be careful
3m%43 l f t c ~ ) ~ h % l ~ ~ % ~ L T < t t $ L \ ~ not to make the impeller blades bent or damaged
3.3.2.4 Disassembling, cleaning a n d
inspection
Dismantle the turbocharger from engine,
disassemble, clean, and inspect it in
accordance with following sect.4.

3.3.2.5 Cleaning and inspection of oil filter &


engine oil change
In accordance with instruction manual of
the engine manufacture.

3.3.2.6 Inspection of oil pipe system


Check up the clamped parts for tightness
and oil leak from oil pipe connections.

3.3.2.7 Inspection of intake a n d exhaust


pipe system
Check up the clamped parts for tightness
and air & gas leak from pipe connections.

3.3.3 Operation figure of engine


I t is advisable to keep a close check on the
whole engine data and record it in a logbook,
since this allows conclusions to be drawn
regarding the condition of the turbocharger.

If these data deviate appreciably from


earlier figures, find out t h e causes.

The following should be entered in the


engine logbook.

Output of the engine


Engine speed
Air inlet temperature
Pressure of charged air
Air temperature after compressor
Air temperature after charged air cooler
Exhaust gas temperature after cylinder
Exhaust gas temperature before
turbocharger
Lubricating oil temperature before
turbocharger.
. Lubricating oil pressure a t the inlet of
turbocharger or the outlet of
4. Maintenance

4.1 Cleaning

Safety instruction

When handling detergent, solvents, acids


and alkalis be sure to observe the respective
safety directions on the manufacturer's
label and in the operation manual. Observe
also the instructions for the
environmentally compatibly storage and
disposal of these substances.

Warning!
Cleaning works should be carried
outdoors due to explosion hazards. If this
is not possible, ensure that there is
adequate ventilation.
Before beginning cleaning work in
confined spaces, extinguish naked flame
(including cigarettes!) due to the danger of
explosion.
Always wear protective clothing.

4.1.1 Turbine shaft(1001), casing(3001,4001)


and compressor wheel(2001)

aDip the parts in warmed solvent to make


deposit soft.

aRemove the deposit with a plastic scraper


or a hard-bristled brush.

O Take care of damaging journal of turbine


shaft and seal ring way.

Caution!
Do not use a wire brush except for Turbine
wheel and Shroud part of
Turbine housing.

4.1.2 The other parts and filter of silencer


(8002)
Clean them in light oil.
4.1.3 Notice
aDo not dip a silencer(10001) in solvent.
O T r a d e a 0-ring(5006) i n for a new one
after disassembling.

@Clean all parts by blowing air and wipe


them by waste clothes after washing.
Especially, clean the oil passage in the
bearing casing(500 1) and the thrust
bearing(7002) by blowing air.
r Turbine housing 1
4.1.4 Mhk33%%a)$ESR3 4.1.4 Instructive points of overhaul
It is recommendable to have overhaul cleaning and
fi9f!?%%mllZl $ k L T 4800 @M@%I$%L inspection at every about 4800 hours use. In case
b b h ' W h h ' f L L \ % P l t Z B h\I;a)IH3SQ heavy contamination is found, the interval of
~~!lF%%ifi%LT<t<$L\~ overhaul should be adjusted as occasion demands.
Mf!?%%e. 9-k'>/\35>!f9173 FS%!& Be careful the carbon covered over the shroud part
m?%T$L\o of turbine housing is quite hard to remove it and
looks like metallic surface.
f j ' x m m r c t s a (IU-~~>) ~ ~ % ~ L T L \ G
L\h\@3?LT<t<$L\0 Check if there is groove due to erosion on the
surface of gas passage.

it;tlD9-f>o-9fiX&U3SZfi9IJ75>X Radial tip clearance at gas outlet part

Clearance R

~4W2-j
Measuring
Position
"2

R3
: Clearance gauge li

Please
+-f>Rt$~S7jt~.i-)~~)>Yjg${$~[z check and clean if carbon and sludge of
I
~ - ~ ~ > + ; . ~ ; ~ ~ ~ a ) ~ ~ . 2 ~ 4 ~ ~ oil
lubricating f Caccumulate
t ~ h <at#back + ~wall
~ ~ of turbine
I
I L\%L\h\@sL. #$!!!LTL\6%f%l$.EfYl)BL\T impeller and groove of seal ring.
(Refer to Sect.4.1.6)
i 7;$L\, (4.1.6 IRgR?)
\ This part must
6 o a k only turbine
wheel part up to be covered by
rear wall in hot rust preventive
water or carbon oil.
removal solvents.
ra>%mcaY Y
-x%a>G$EH
r4%&l]2B;ffli
L
lXS.F-6

For reference ; Standard dimension


$%- ; @%& El BlE

Usable Unusable
#l%E45!?H
V%&8?1 dI%EEH;f;q%f~8f&
+,J
~ ~ ~ ~ j g ~ ~ S - e ' > R ~ $ ; p 7 k & jIncaseofturbinewheelcleaning
@ ~ - ) ~ . ' J M ' B ~ B )U
>SL'YYd>hg?@.'j@%%l
@ .
-

<E$L\, tg:ghf&h\T%L\ige, @&hf


%*Y&bc-khf&jl)%%.(Fig.4s.B.E)
~~
-9
3 hT\ 6
%~I=g'')-x
-1~
&~\l$~ bysoakingin

ring to the end of compressor-wheel side


hot
water or carbon removal solvent, rust preventive oil
must be applied to the turbine shaft from groove for

before soaking of it. If protection is not enough,


corrosion can be occurred. (Refer to Fig. 4)

5-)L'J>'"tBrlMr*"LT7;tt\0
~*ahcm6tge'b*@q5154xL)BL\T7;t
* Seal ring must be replaced at every overhaul and
remove the carbon deposits from sealing groove, if
accumulated. As for the wear of sealing groove of
L\o turbine shaft, refer to Fig. 5.
fi, S - ~ > U - ~ @ . ~ - ) L ~ D @ $ E I Z ~ L \
TI$ Fig. 5 ?~~+~&IzLT<~~$L\~
Air wire brush
4.1.5 ~ - I ~ . > ~ ! ~ I D ; E % I L ~ L \ T 4.1.5 Cleaning of Turbine side parts
9-C'>/\39>YD.ia73F3+9-f>gB Carbons at shroud part of turbine housing and
l = l ; t ; h ) L - j 3 A ' c s / ( + 9 3 ~ $ g $ - ~ / t : ~ g ~ , turbine
h- wheel normally include very hard layer of
Calcium and Vanadium. Therefore clean them by
it;'>Ehc%+8LbTDT. B ~ \ 7 4 t 1 7 5 + ~ 3hard wire brush or scraper. (Remove the dropped
b-"IcTTOlzflkLT<t<$L\o ( 3 deposits in turbine housing surely after cleaning.)
5 > Y ~ l = B % t c 3 % h h ~ I ; t : IEzf~ x ~ ) ~ % L \ T <
t:$L\o )

4.1.5.1 ;E%D+IIRIZTL\T 4.1.5.1 Cleaning procedure


9-C5>R* (;EE{$II:Photo 6) Turbine wheel (Sample after cleaning: Photo 6 )
1) @L\7 ~ Y ~ ~ ~ + X ~ L - / ~ I Z T T S1)I ZRemove
~ - the carbon carefully by wire brush or
scraper.
$>g%kLr<t:$~\.
2) h-$>hCBkLl=<L\%el$ 4.1.4 1B FIG.4D 2) If it's hard to remove the carbon, soak only
Z$BT9-~'>%3fZlf%jE7K&6L\l;t:h-# turbine wheel in hot water or carbon removal
>@~~lII=~~L-C<f~$L\. solvents according to Chap. 4.1.4 Fig. 4.

.9-C'>/\39>9'(5173FS) Turbine housing (Shroud part)


1) @ L \ 7 ~ Y ~ ~ ~ + X ~ ~ - / ~ I Z T T1)O Remove I Z ~ the- carbon carefully by wire brush or
scraper.
*>gzkL-C<t:$~\~
2) h - $ > h C % k L I ~ < L \ % ~ l t 3 1 ~ % 1 ~ 5 % f + 2) If it's hard to remove the carbon, penetrate the
%E-EkZWC5a5+3Flz;%~+~&E~SBS-@T< cleaning solvents in way of covering by wet rag
tZ$L\, that is soaked with solvents.
3) Photo 7, 8 l$r7'-7d?155TD3W%D@
3) Photo 7, 8 show a sample of utilizing cleaning
TTT, Z f Z $9 2mm/l *hC30*$ZE%kh tools. This pneumatic tool that has bundled about
;hT&L), T/H fj'X~@&Dh-*>&~?~* 30 wires (2mmlpc) works effectively to remove
5\~bflkLl:&PhT$0 L D & j % Z 5 E g @ M
carbon deposits on gas passage. Use it not to
$;hQ%el;t;/\35>YD@+agEll~)4xhaL\ damage material of turbine housing itself. Also do
6, IiELT12FH LT<t<$L\. not use it for cleaning of turbine wheel in order to
prevent the damage for turbine wheel
I%, B+~E~",&~~~~I~~C&LI~TDT~-C'>~
$D~$?%l=I${%RL%L\T<t2$l\o

A Caution
The degree of contamination on turbine wheel and
its surrounding area differs from the individual
operating condition. Even after the certain running
hours shorter than the recommendable overhaul
interval, thick carbon may accumulate on turbine
wheel and the area surrounding it. Excessive
unbalance causes touching of turbine impeller and
compressor wheel at shroud part, which may lead
to damage of bearing part. Therefore special care
should be taken so as to overhaul and clean
earlier for prevention if engine is running with
heavy fuel oil.
Remove the carbon deposits on turbine wheel
evenly as much as possible. Uneven cleaning
may cause the unbalance of rotor.

ij&$%&,M I Q B ~ ~ R ~ I z ~ - I ~ ' > ~ - ~ ~Confirm


+ B L that the rotor can turn smoothly by hand
L-C51)fEh\l)h~%<@<Bb~kE@i2L~<t:$ after cleaning.
L\o

In case of the coated turbine housing, do not


i84$9-t'>/\35>'/K6(D%%. 5173F3 damage or tip the coated parts when cleaning gas
UM~fiXS%%BmE3EE$QEIkiB4;f6PEB passage.(Fig 3 %pos.l)
;&$eftL). 1Z3If fcl)L%L\61=3f ZzL-C-F$
L \ , (Fig.3 %Posl6fl)
PJ Seal ring and
groove

Fig. 6 Seal ring part


Temp. ("C)

>
oking range gine stop with
engine stop without cooli ,
a. L......u-kb&u&Ati*

down 779-9-1) 29
779-3-Y >Yes
1

I
I

I
I
i
b
Time

I LO stop I
4.1.6 9-)L%a)h-Tf;>@;fa
. 4.1.6 Accumulation of carbon deposits
B M i $ k 1 2 9 - f > ~ - 9 (9--E>EE) h \ h a Oil leakage or bearing damage can be occurred by
~ E B I = A ~ I . ~ - ) L ~ T ; M ~ B ; B ~ I - + > ~ 'ofBlubrication
coking ~ ~ ~ oil around the sealing section,
because of heat soaking from turbine impeller after
E~11~~iEh'cs@9~W1~h~WY~6srl%II'Yh~&sLI engine stopped.
ST0 Photo 10 shows slightly coked deposits in LO space
Photo 10 I&dPl)>9'i'/ \35>9'5-)~1)>9*3 around seal ring at turbine side
LO E ~ I / ~ \ ~ B I c ~ L \ IL. -%+ > ~Photo
~ ' 11
~and
~ ~12:
~ WAfter
Y cleaning. If accumulated
EL-CL\6!ik%Tq0 carbon deposits are observed around it, remove
deposits and do not damage the sealing surface.
The seal ring must be renewed at every overhaul.
Photo 11, 12 I&j%ELt=%UlTq,
33l~h-Tf;>h~~;f~L~L\6~~1~5-)~31~
ES~~+ITGL\A~A-*>~~~IRL\-C<~:~
L\, fi, 5 - ) ~ 1 ) > 9 ' l & ~ f i @ I ~ Z ~ L - C < t z $
L\o

I - - + l / y . ~ ~ ~ g + a r ; , f a~gkit;i~=
~tC~, In order to mitigate the coking phenomenon, idling
/n\P~71311a)T4FI)>~+LEt$~Ldb.
PE)
15
(Fig.6 than,
operation before engine stop is recommended for
minutes.
(Ref. Fig 6)
7 4 F ' 1 > Y + i Z h i T V B t d % t l & ~ > 9 > @ I t in case it is impossible to do idling, start a priming
~ 'n'ra'fu
$ ~ & f ; l = ? s 4 ~ > Y $ > y %15 % b ~ f ' ,pump as soon as engine stopped and supply
b B % & l : ~ M ~ f i i B % i & % L ~ T 2 ~(Sit!l
\~ ) Lub. oil for more than 15 minutes.
(Remark 1)

:it2
/IUL
I Remark 1
+
I
Such priming pump may automatically or always be
B M G l t l-Y74l>9%>Yh~$M4kMbtr operated during standstill according to the engine
I & ~ e ~ ~ ~ L - c ~ \ 6 B M * ~ ~ Lspecification.
\ ~ * a ~ For~ ~theL detail,
< I ~consult with engine

A Caution
In case the engine is forced to stop emergency, the
following measures must be done.
Cooling-down by Lub. oil-priming pump should be
done immediately.
Before re-starting of the engine, check the rotor
condition according to Sect. 3.3.2.2 (Inspection at
every 1200hours) In case abnormal condition of
rotor is observed, carry out the cleaning and
overhaul inspection of the turbocharger.
4.2 Tools

4.2.1 Necessary tools

4.2.1.1 Special tools (supplied by IHI)

Designation Quantity
Turbine shaft locking tool - - - - - - - - - 1
Seal ringpliers . . . . . . . . . . . . . . . . . . . . . . . . 1
Snap ring pliers - - - - - - - - - - - - .1- - - - - - - - - -

4.2.1.2 General tools

Open ended spanners (13117119)


Torque wrench (13mm,24.5 N.m)
Torque wrench (l'imm,29.4 N.m)
Torque wrench (17mm,38.2 N - m )
Torque wrench (19mm,78.5 N - m)
Torque wrench (30mm, 127.5 N. m)
: Left-hand thread
Torque driver (8.0 N.m)
Plastic hammer
Screw driver

4.2.2 Measuring tools

Magnetic base
Dial gauge
4.3 Weights

A warning!
m4mBfi%&u%2Bfi%%&%elA. +?+G Attach individual parts and large component
modules carefully to suitable lifting devices,
rnES.tYhfd3L1, AmmaL\% Y IIfZR%@H which are in technically, perfect condition
<
L-C t?$L\.
and which possess adequate loading-bearing
di.=.,8 s;h-r:L\a%#a>7;rzrgzifGL\L\< i.. capacity.
$ L\ (3%1 1 % @ R< 75%Ll). Do not stand under suspended loads (refer to
chap. 1).

Table 2. Turbocharger
r/ ?l-g$3433,%*E~%Z!E,z,
Turbocharger complete with silencer I

Table 3. Weight of assemble


SB
Designation Weight
[kg]
/
7 i 7 L - y Y / \ r f Y i Y (?4 71--+f'!$) $958
1 Compressor housing (including Diffuser) I
I
I
47 1) i Y / \ 9 Y i Y/Bearing housing J!# 84
9 - F i/\ 9 Y i !f/Turbine housing $940
'ri E%Z/Silencer $933
4.4 i3t%@%a 4.4 Disassembling the turbocharger
{;fQ 8. g$$#%/,f#$E16BE@,RT?5L~o -Refer to fig.8, Disassembling and
-
assembling..

A Warning!
Attach individual parts and large
m e @B;sla"a%ctroA41!%&E%b%efd;
+%?A component modules carefully to suitable
0 , Rl%a7.ckt~i3
atij@SWfi-% 0~ C ~ S S E @ H lifting devices that are in technically perfect
L Z W Cl. condition and which possess adequate
% k ,I % ? ~ ~ T L ~ ~ # J @ C ~ > ~W; zI .TZ~\ t~l T
, 7; loading-bearing capacity.
S blo Do not stand under suspended loads.

4.4.1 %lI'd-b$fif5?D%% 4.4.1 Branch position


B$$$%k21j>' j-QIl5?4$4k% 1: k T &!J- >; Mark the turbocharger casing first so that it
9' D $ H ~ $ ~ ~ P u ? Z ~IS;P~~I~T
@L ~ ~ T Q
Rl I ? " , may be reassembled in the same location
kA%;it=&\T$??-9g9 t-f~F?5
tl, from which it is removed.

4.4.2 Removing silencer (1000 1)


-Refer to fig.8-1

a/';;%&*
kb(10003), i2Ija%&(10004) E15x%T0 a Remove hexagon bolts (10003) and spring
lock washer (10004).
@Pi %%$4*(10001) EK?%'Tf.
@ Remove silencer (10001).
A S f ! Caution!
Take cares no to damage the punched metal
when dismantling silencer.

4.4.3 Removing compressor housing


(3001)-Refer to fig.8- 1

ORemove hexagon head bolts (3003) and


al<%$)Lb(30031, kfk2@&(3006) g4x%T0 spring lock washer (3006).
@fig%IL b (3021). bf&2@&(3006)Q r f ~ 9 - T ~ @Remove hexagon head bolts (3021) and
07j71/~ ! f 1 \ 3-i"iY(3001)??flft%T spring lock washer (3006).
A @ Remove compressor housing (300 1).

Caution!
~ i 7 L~tfl\g:/'
' ;/3*(3001)E B % T m , Ji7O L ~ t f 4 i 3~ "
(200i)E@3t37F6t~k5 CZ&BLTTStl. Take care not to damage the compressor
blades (2001) when removing compressor
housing (3001).

4.4.4 Removing diffuser (8001)


-Refer to fig.5-1

aRemove a cross-recessed head screw (3007).


a Remove diffuser (8001).
A, S f ! Caution!
Do not remove diffuser (8001) except for
inspection or replace.
4.4.5 9- L
>fRr]4%4$@P(11006)~')4%% 4.4.5 Removing turbine side foot (1 1006)
- 4;fkl 8-2 a!!%<
Eti t j , -Refer to fig.8-2

ai?fi&)L F- (11019), C~da@&(llo2o)E~~9~ a ~ e m o v ehexagon head bolts (11019) and


To spring lock washer (1 1020).
@p- 54PflT.
i#!114~4~f~~(11006) @ Remove turbine side foot (11006).
@4x4$7ii>"l1008> & 4 9~%To @ Remove clamp(11008).

A Caution!
Before removing turbine side foot (11006),
insert a support under turbocharger.

4.4.6 Pulling out compressor wheel (2001)


-Refer to fig.8- 1

D I n s t a l l turbine shaft locking device to gas


outlet flange of turbine housing.
@ Remove shaft end hexagon nut (1008). This
nut is left-hand threaded.
@ P u l l out compressor wheel (2001). When it
is difficult to pull out by hand, heat
compressor wheel(200 1) evenly below
100C.

4.4.7 Removing seal ~ l a t e ( 6 0 0 1 )


-Refer to fig.8- 1

O R e m o v e hexagon head bolts (5003) and


o;ifi$* I1 b(5003). C%d2@4?(5004)E 4 9 f l T 0
spring lock washers (5004).
@ j ? ~ f iL f~f;;%$'-lbb(5003) 2 /t\Q)T L kLfh' ICb
@Using the removed 2 bolts, push up seal
2 LTFFJtj, ?-11/7' 1 / - b (6001) k ? b @Q(1006) plate (6001) with sealing bush (1006).
E -%l:4xCKnT0

4.4.8 Removing thrust collar (1002) and thrust


4.4.8 XjXb$i-(1002), X j X b ' 7IJj3' (7002)CT)@% L bearing (7002)
- 4\jH 8 - 1 @F,E-f$tjo -Refer to fig.8-1

0 x 7 bhi-(1002)
~ (33/J01/5~94111)&4P%TO O ~ e m o v ethrust collar(1002) (compressor
@>-1/7O 1/-bIf~f$)fl/kfi$-11/b(5003) 2 *&$T L k side).
Lf$'I b b 2 LTRl t l i l b q " 7'12~'( 7 0 0 2 ) G q ~ f l
J, @Using the removed 2 bolts (5003) for seal
To plate, push up thrust bearing (7002).
@ l i R bhi-(1002) ($h@4Hrl) & 4 ? % T 0 @ Remove thrust collar (1002) (bearing side).

4.4.9 Removing turbine housing (4001)


-Refer to fig.8-2

a) Remove hexagon head bolts (4003).


@ Remove turbine side clamps (4002).
@ Remove turbine housing (4001).
3-k>il\9?*i 3 4 ( 4 ~ ~ l ) Q R ~ f l L 7 5 3 0 % f ~ @ ~ i ~ . When removing is difficult, tap the turbine
7 O

j l f ~ 9 h j 7 T 9 - k jll9>"
' <
>!I+ (4001)9\j31&$$ DPL] housing (4001) by using plastic hammer. :
A Caution!
The material of the bolts (4003) for turbine
MO$'Jbb
kb(4003)1.2ifi$%~;t6CT)~,
I;;@J$' housing (4001) is heat resisting steel,
L;tstlck5 I Z L T T S tl. therefore do not mix them with other bolts.

4.4.10 Pull out turbine shaft (1001)


-Refer to fig.8-2

4.4.11 Removing heat shield (5005)


-Refer to fig.8-2

When removing is difficult, tap heat shield


5 0 0 5L7 5 % 7" i X f \ ~ (5005) by using plastic hammer.
<
31\i?T@ WL)-CKY%LTTSt J,

4.4.12Removing seal ring (1009,1010)


-Refer to fig.8-3

4.4.12.1 Removing seal ring (compressor side)


(1010)

ORYFK\L~>-ICJ' 1/-b(6001)J3~I;?dl%J1
;U(1006) a Remove sealing bush (1006) from seal
E4xflT0 plate(600 1).
@?ma 0 <1006)fi~1;3i7'I/rtlllj>-ll'li?' (1010) @ Remove seal ring (compressor side)
??/rf%$?S$Q'/-JL1Ji!7+ 7" i4PTEIxfl'Tf0 (1010) from sealing bush (1006) by using
seal ring pliers which is supplied as a
tool.

4.4.12.2 Removing seal ring (turbine side)


(1009)

@ Remove seal ring (turbine side)(1009)


from turbine shaft (1001) by using seal
ring pliers which is supplied as a tool.

A Caution!
&>-klJ;3' E>-kIJ;13' 7" 74PTEl.-fbiZj+?,&\T When removing seal ring (1009,1010) by
:/-~blJi3'E E % T Z X , 3BCT)fidftJab%;t~tl using seal ring pliers, hold seal ring by
k 3 CZ L T T S tl. finger, not apply excessive stress.
H&@,9-k*j@l]>-lblJ;3*k2%@LT < T?S t l o Seal ring must be replaced during overhaul
inspection.
i 4.4.13 q' 7113" % ; p c 3 f t @

01f377' IJj?*
7' ilPTEIxfl-if,
- {TJW 8-4 $3&-F 2 t 1,

'J)P'
(5002)&%fi$Eg$lmAf~~ 7~
4.4.13 Disassembling bearing -Refer to fig.8-4

aRemove snap ring(5002) by using snap


ring pliers, which is in the tools.

A Caution!

7' 34?%%Tk:7U- Eq' 71Ji3' (7001)%EiiE@3 Take care to prevent damage to semi-float
t-t?&tjck 5 LTTS Lj, Bearing(7001) by using pliers.

aRemove semi-float bearing(700 1).


Caution !
Handle these bearing parts with care to
prevent damage.
4.5 Reassembling the turbocharger
-Refer to fig.8, Disassembling and assembling

Reassemble components after cleaning. Check


and replace the damaged parts if necessary.

4.5.1 Reassembling bearing -Refer to fig.8-4

a Install semi-float bearings (7001) in


bearing housing (5001). Before inserting the
semi-float bearings (70011, dip them in the
lubricating oil.

Caution!
Turn the openings of semi-float bearings
(7001) to inside and install them in bearing
housing (5001). Make sure the openings of
semi-float bearings(7001) are surely put in the
pins which are installed in bearing
housing.

@ Install snap ring (5002) in bearing housing


(5001) by using snap ring pliers.

Caution!
Make sure snap rings (5002) are firmly
seated in bearing housing (5001) grooves.

Install snap rings (5002) in the direction


that the smooth rounded surface to the
semi-float bearing (7001).

Turn gap of turbine side snap ring (5002)


to the left seen from turbine side and
compressor side snap ring (5002) to right
seen from compressor side.

Take care to prevent damage to semi-float


bearing (7001) by using pliers.

Make sure the slight movement of


semi-float bearings (7001) after snap rings
are installed.

4.5.2 Reassembling seal ring (1009,1010)


-Refer to fig.8-3

4.5.2.1 Reassembling turbine side seal ring


(1009)

a Install seal ring (1009) in turbine shaft


groove (1001) by using seal ring pliers.
I
1 4.5.2.2 337' b~tf#lrl9-JClJ;3' (lolO)@Bi$I.f 4.5.2.2 Reassembling compressor side
seal ring (1010)
oW/lY) (1006)i: ~ i 7 l/~ttl~ll:/-~b'Ji9/'
' (1010) ??
%-A:( Z !t $05- JLIJ j9' 7' i4'fTR~1\f
l3Q a Install seal ring (1010) in sealing bush
groove (1006) by using seal ring pliers.

A caution!
When installing seal ring (1009,1010) by
$59-k11i3'(1009,1010)E7" jl'fTfxi;tf5#e,
1 using pliers, always hold seal ring by finger.
, &~-3%%T3ATT2 L j O

4.5.3 Reassembling heat shield (5005)


4.5.3 ~ % E ( ~ o o ~ ) C T ) Q-I I t;fB
.~ 8-2 @!!! F
-Refer to fig.8-2
$5 L l o
a Install heat shield (5005) to bearing
housing (5001).

4.5.4 Reassembling turbine shaft (1001)


-Refer to fig.8-2

a After installing seal ring (1009) to turbine


shaft (1001), install turbine shaft (1001) to
bearing housing (5001) from turbine side.

A caution!
Before installing turbine shaft (1001), apply
lubricating oil on the shaft.
Turn gap of seal ring (1009) to upwards.
Before installing turbine shaft (1001),
ascertain that there is no foreign body in
the bearing housing (5001).
For safety inserting of turbine side seal
ring (1009), vertical installing of turbine
shaft (1001) is recommended. At inserting
of turbine shaft (1001), place the center of
it to the center of turbine shaft (1001).

4.5.5 Reassembling turbine housing (4001)


4.5.5 9-k'i1\fi9';3'(4001)CT)&3 -Refer to fig.8- 1,8-2
-
!$[;;<I 8-1,8-2 &!,f! F s t),
a Install turbine housing (4001) to bearing
Q$jfi!($jCt=EPL 7 ~ g ? - ? C e g h ? & ~ " /i:lii'/:/"
k ig" housing (5001) by aligning the mark.
(4001)E2" 7IJj9' ji95~ (5001)~Z$H&.&O~ @ Install turbine side clamps (4002) and
a9 k' j4RllFP 5 %&(4002)% d; aAP4 $' Ib b(4003) hexagon head bolts (4003). Tighten bolts
??flL?I.ftfZ I ~$%i;fb!b9kZ78.5 (N-m) ?'To by 78.5 (N.m).

I A aw! Caution!
fie$'~bb(4003)t~ t3, ??%%?ti
Ri$ISkk@J L TT2 t 1. Apply seizure prevent compound on
bolts(4003).
U-$'+H'& L T %
319 k >D-!?L&l'&E~??If~f~ftf,
<, @ Install turbine shaft locking device.
4.5.6 Reassembling thrust collar (1002) and
thrust bearing (7002)
-Refer to fig.8- 1

a Insert thrust collar (1002)(bearing side) to


turbine shaft (100 1).
@ Set thrust bearing (7002) into the knock
pin (5007) of bearing housing (5001).
Apply lubricating oil on the thrust bearing
(7002). Install thrust bearing (7002) to
bearing housing (500 1) with aligning
lubricating hole.
@ Insert thrust collar (1002)(compressor
side) to turbine shaft (1001).

4.5.7 Reassembling seal plate (600 1)


-Refer to fig.8- 1, 8-3

a Insert sealing bush (1006) in seal plate


(1002)(compressor side).

A Caution!
T u r n gap of seal ring (lO1O)(compressor
side) to upwards.

@ Insert "0" ring(5006) in the groove of


bearing housing(5001)

Caution!
Do not to be twisted "0"ring (5006).

@ Install seal plate (6001) inserted sealing


bush (1006) to bearing housing (5001).
@ Install spring lock washers (5004) and
hexagon head bolts (5003).
Tighten bolts by 29.4 ( N - m ) .

4.5.8 Reassembling compressor wheel (2001)


-Refer to fig.8- 1

a Insert compressor wheel (2001) to turbine


shaft (1001).
@ Install shaft end hexagon nut (1008) to
turbine shaft (1001). This n u t is left-hand
threaded. Tighten bolt by 127.5 ( N . m ) .

Caution!
After installing compressor wheel (20011,
check clearances i n axial and radial
direction.
(Refer to sect. 3.3.2.3.)
4.5.9 Reassembling turbine side foot (1 1006)
-Refer to fig.8-2
a Insert clamp(11008) to turbine
housing(400 1)
@ nsert turbine side foot (11006) to turbine
housing (400 1).
@ Insert spring lock washer (11020) and
hexagon head bolts (11019). Tighten bolt
by 24.5(Nam).

4.5.10 Reassembling diffuser (8001)


-Refer to fig.8- 1

a Install diffuser (8001) to compressor


housing (3001).
@ I cross-recessed head screw (3007).
Install
Tighten screw by 8.0(N.m).

4.5.11 Reassembling compressor housing


(3001) -Refer to fig.8- 1

@ Install compressor housing (3001) to


bearing housing (5001) by aligning the
mark.
@ Install hexagon head bolts (3021) and
spring lock washer (3006).
Tighten bolts by 38.2(Nmrn).
@ Install hexagon head bolts (3003) and
spring lock washer (3006).
Tighten bolts by 38.2(Nem).

4.5.12 Reassembling silencer (1000 1)


-Refer to fig.8- 1

aInstall silencer (10001) to compressor


housing (3001).
@Install hexagon head bolts (10003) and
spring lock washer (10004). Tighten bolt
by 29.4 (Narn).
5. Faults

5.1 Symptoms of faults and possible causes


When any troubles have occurred in
turbocharger, its function can not be
obtained sufficiently. I n such case, after
making sure t h a t there is no abnormality in
the engine, check turbocharger in
accordance with the following procedure and
take a n appropriate measure.

5.1.1 Exhaust gas temperature higher than


normal or charged air pressure lower
t h a n normal

Possible causes;
a Dirty filter of silencer(10002)
a Dirty compressor wheel(2001) or
diffuser(800 1)
a Damaged turbine wheel
@ Exhaust back pressure too high
5.1.2 Vibration or noise of turbocharger larger
t h a n normal

Possible causes;
a Heavy dirty or damaged turbine wheel
a Heavy dirty or damaged compressor
wheel(200 1)
@ Damaged bearings
@ Bad fitting of air and gas piping
a Bad fitting of turbocharger

5.1.3 Lubricatiqg oil pressure too low

Possible cause;
a Dirty or clogged lubricating oil filter

5.1.4 Too large lubricating oil consumption

Possible causes;
a Too high lubricating oil pressure
@ Worn seal ring(1009,1010)
@ Bad fitting of lubricating oil piping
5.1.5 Surging of the compressor

Possible causes;
a Increase of the friction resistance in the
charged-air cooler or air filter of
silencer(10002)
6. Cleaning the compressor wheel in service

6.1 General
Compressor wheel should be cleaned
periodically.

The cleaning interval differs depending upon


operating condition, but it is suitable to clean
about once a week in service.
The compressor wheel can be cleaned during
operation by injecting water.
If the deposit is very heavy and hard, the
compressor wheel must be dismantled for
cleaning.
The injected water does not act a s a solvent;
the cleaning effect can be achieved by the
physical impact of the drops on the deposit.
Use "Blower Wash" or clean water containing
no additives either in the form of solvents or
softening agents.

a Caution!
Regular cleaning of the compressor wheel
prevents or delays the formation of a deposit;
b u t it does not eliminate t h e need
for normal overhauls, for which the
turbocharger h a s to be completely
dismantled.

6.2 Procedure

aOpen all drain cocks in charged air pipe.


aThe water should be injected during the
engine is running warm and a t the highest
possible load. (above 75 96 load)
@ For a n effective cleaning, inject all the water
required within 4 to 10 seconds. This water
quantity is 0.3 (liter) for RH1831203.
@ For injection a hand-pump or a vinyl injector
may be used. The specified water quantity
should be observed, because entering
uncontrolled water to turbocharger and
engine causes a trouble.
@ Either charged air pressures or exhausts gas
temperature changes after injecting water.
@ I f pressure or temperature does not change,
it may only be repeated after 10 minutes.
@)There is no change in performance even
repeating 3 or 4 times injection, which
causes the deposit to be very heavy and hard
or the compressor wheel to be damaged. In
this case, the compressor wheel should be
dismantled for checking or cleaning. After
injection, the engine should be r u n loaded for
a t least 15 minutes.
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