6 Turbocharger Overhaul

 

MAINTENANCE WORK INSTRUCTION Job Title: Amos Component Name: Maker Component Name: Location:

R-652-0533 - D/G - Replace The Turbocharger Bearings DG2 Exhaust Gas Component No.: 652.053.001 Turbocharger  653.053.001 Turbocharger  Component No.: 156

ER, 3rd deck 

Frequency:

Resp. discipline:

Man power:

Prepared by: Approved by:

Revision: Date:

Maintenance Task  K System code Part or system (W9L20DFA - Instruction Manual) AMOS Turboc Tur bocharg harger er Replac Replacee the the turboc turbochar harger ger bearin bearings. gs. 24K  156 See manufacturer's instructions.

24000 hrs

Manual Chapter

Remarks

Chapter    15

24K 652.053.0 652.053.001 01 DG2 Exhaust Refer to KBB makers manual for detailed explanation on this maintenance 7.5.4 653.053.001 Gas Turbocharger  7.5.12 Cleaning Checking of rotor & bearings Replacement of bearings Checking of housings Contents

2. TIGHTENING TORQUES AND CLEARANCE................................ CLEARANCE....................................................... ................................................3 .........................3 7.4 Clearance sheet....................................... sheet............................................................. ............................................ .................................................................. ............................................3 3 3. SPARE PARTS CHECK LIST................... LIST .......................................... ............................................. .................................................................. ............................................4 4 8.2.5 Bearings (4000)........................................ (4000).............................................................. ............................................ .................................................... ....................................... .........4 4 4. TOOL CHECK LIST................................................. LIST....................................................................... ............................................ ............................................ ...............................5 .........5 Tools for turbocharger............................................ turbocharger.................................................................. ............................................ ........................................................5 ..................................5 8.3.1 Tool Set (9800)....................................... (9800).............................................................. ............................................. ............................................ ........................................5 ..................5 5. REFER DOCUMENT.............................. DOCUMENT.................................................... ............................................ ............................................ ........................................ ..........................6 ........6 7.5.5 Disassembly of the complete turbocharger............................................ turbocharger.................................................................. ......................................6 ................6 7.5.6 Assembly of the complete turbocharger............................................ turbocharger.................................................................. ..........................................6 ....................6 7.5.7 Assembly and disassembly of the silencer or air-intake housing............................... housing................................................ .................7 7 7.5.9 Assembly and disassembly of the compressor housing............................................. housing...............................................................8 ..................8 7.5.10 Disassembly and assembly of the cartridge....................................................... cartridge...............................................................................9 ........................9 7.5.11 Disassembly of the rotor, complete.......................................................... complete......................................................................................... ...............................10 10 7.5.12 Assembly of the rotor, complete........................................... complete................................................................. ............................................ .............................12 .......12 8.2.1 Exhaust gas turbocharger, complete (1000)................................................... (1000)............................................................................ ...........................15 ..15 8.2.2 Exhaust gas turbocharger, basic unit (1100)............................................. (1100)..................................................................... ................................ ........16 16 8.2.3 Cartridge (1200)........................................ (1200).............................................................. ............................................ ............................................. .................................... .............17 17 8.2.4 Rotor (2000)...................................... (2000)............................................................ ............................................ ........................................................... ............................................ .......18 18 8.2.5 Bearings (4000)........................................ (4000).............................................................. ............................................ ................................................. ..................................... ..........18 18 8.2.8 Gasket set (9910)............................................ (9910).................................................................. ............................................ ..................................................... ...............................19 19

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1. MAIN JOB STEP INSTRUCTION 1. Preparation: 1.1 PTW, IC, JHA 1.2 Tool list 1.3 Spare part list 2. Is Isol olat atio ion n Follow 4K,8K isolation 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 3. Jobs Engine attachment for 9L20DF (Turbocharger) Engine attachment for 9L20DF (Turbocharger) 3.1 7.5.5 Disassembly of the complete turbocharger 6 3.2 3.2 7.5.7 7.5.7 Asse Assemb mbly ly an and d disas disasse semb mbly ly of the the sil silen ence cerr or or airair-in intak takee hou housin sing g 7 3.3 7.5.10 Disassembly of the cartridge 9 3.4 7.5.11 Disassembly of the rotor, complete 10

3.5 3.6 3.7 3.7

7.5.1 .12 2 As Assembly of of th the ro rotor, complete ete 12 7.5.10 assembly of the cartridge 9 7.5. 7.5.6 6 Ass Assem embl bly y of of tth he co comple mplete te turb turboc ocha harg rger er 6

4. De-i De-iso sola lati tion on 5. Follow 4K,8K de-isolation 4.1 4.2 4.3 4.4 4.6 4.7 4.8 4.9

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2. TIGHTENING TORQUES AND CLEARANCE 7.4 Clearance sheet

 New condition Clear

Parts designation mi n max Compressor impeller – compressor 0 .5 5 0 .6 5 1 housing (radial) Compressor impeller – compressor 0.6 0.7 2 housing (axial) Tilting clearance (rotor – bearing)