IHI Exhaust Gas Turbocharger

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turbocharger manual...

Description

aaax9-r)aiett~ EXHAUST GAS TURBOCHARGER

R%S TYPE

RH183/183L/203

(Version : Y

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)

71Jj3' n92'

8'

( t 5 7 ~ - - b 4 7 ? 1>Y)

Bearing housing with foot (Semi-f loat bearing)

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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 J-f-f 5-Y FR3ea

TSU Turbo Systems United Co., Ltd. Tokyo East Japan Service Dept.

TEL FAX

03-5611-5983-5986 03-5950-0491 (24hrs) 03-5611-5997

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

East Japan Service Station TEL FAX

03-5619-5021 03-5619-5022

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

Kobe West Japan Service Dept. West Japan Service Station

(fi~*Y-cx%) TEL 078-200-3092 FAX 078-200-3096

3-2, Wakihamakaigandori 2-chome, Chuo-ku, Kobe-shi, Hyogo 651-0073, JAPAN (West Japan Service Dept.) +81-(0)78-200-3092 TEL FAX +81-(0)78-200-3096

(%EI*Y--Exx7--93 TEL 078-200-3093 FAX 078-200-3096

(West Japan Service Station) TEL +81-(0)78-200-3093 FAX +81-(0)78-200-3096

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Imabari Office

f 799-1506

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3-9-36-303 TEL 0898-48-8750 FAX 0898-48-8751

3-9-36-303,Higashimura, Imabari-shi, Ehime 799-1506, JAPAN +81-(0)898-48-8750 TEL FAX +8 1-(0)898-48-8751

Kyushu Service Station

TEL FAX

092-931-2051 092-931-2052

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

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FOREWORD

To make full utilization of the IHI Exhaust-Gas turbocharger

(hereinafter

briefly

called

"turbocharger"), it is important to comply with the procedures for operation and maintenance 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, Specification

P a r t number and designation Quantity

As stamped on the rating plate of turbocharger (Refer to Fig. l,sect.2-2)

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 turbocharger for damage or leaks.

the

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,.

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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 ~ ~ ~ & Before cleaning, protect the floor against t1&5 cz. [email protected]$~+%l~lU)a>KE$IEL-C< 7Zf Ljo

unintended leaks of oil and operating 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 compressor washing.

dosing

vessel

for

1.2.4

Safety when assembling

disassembling

and

Inform operating personnel accordingly before starting any special or maintenance work. As precaution, place a receptacle leaking oil under the turbocharger. When disassembling, secure against turning.

the

for

rotol-

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 mothballing the turbocharger.

during

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 inspection work

1.3.1

maintenance

and

Mechanical influences

Physical injury

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Warning! Unconsciousness and injury due to: Crushing, shearing, cutting, winding, fragmentation, drawing in, knocking, stabbing, rubbing, loss of liquids under high pressure, under burnt, high temperature, slipping, tripping falling. 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 turbocharger clean

and

Ensure t h e availability absorbing materials.

of

the

oil

-

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

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1.3.3

Noise

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

90dB(A) Protective measures Wear ear protection

in

excess of

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

SO~B(A)

Protective measures Wear ear protection

excess of

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 3L% 83 k;

2.2 Parts list

Table.1 Parts I

1)eslgnation

Parts No

Turbine shaft T h r u s t collar Distance piece Sealing bush Shaft end hexagon n u t Seal ring (Turbine side) Seal ring (Conpressor side) Compressor wheel Compressor housing Hexagon head bolt M10X 35 Spring lock washer 10 Cross-recessed head screw M8 X 25 Plug GI318 Pucking 16.5126 Hexagon head bolt M I 0 X 95 Turbine housing Turbine side clamp Hexagon head bolt M I 2 X 20 S t u d bolt M16 x 55 Hexagon n u t M16 Bearing housing S n a p ring Hexagon head bolt M10 X 45 Spring lock washer 10 H e a t shield 0 ring G I 3 5 Seal plate Semi-Float bearing Thrust bearing Diffuser Silencer Air filter Hexagon head bolt M10 X 3 5 Spring lock washer 10 Turbine side foot Clamp Clampimg spring Hexagon head bolt M8 X 16 Spring lock washer 8

1001 1002 1004 1006 1008 1009 1010 200 1 3001 3003 3006 3007 3010 3011 3021 400 1 -1002 4003 4006 4008 5001 5002 5003 5004 5005 5006 6001 7001 7002 800 1 10001 10002 10003 10004 11006 11008

EXHAUST GAS

IHI

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TURBOCHARGER

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3.3.2.1

400

3.3.2 The points of Inspection

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3.3.2.1 Every 400 hours: Check all fixing bolts

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Note

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1200 @~B?$S:9 - E ' > n - 9 a m $ 6

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This check is to prevent a leakage of exhaust gas ~ ~ ~ - O ~ ~ F Z and lubrication oil due to looseness of bolt and nut.

3.3.2.2 Every 1200 hours: Check the

rotation of rotor -

(Photo 1 )

-

(Photo 1)

A Caution 9 - f > ~ - 9 ~ ~ 5lB\k\L) ~ L ~h?I/*YY~!~/. €I-++RFo : 94+)LY--5ai$ES%&4~6~ : Ca>i$hXtrf~6~

Every 4800 hours: Check the clearance of rotor

) H~~ to measure clearances @Axial clearance

Photo 2 : Push turbine shaft to turbine side end by hand. :Set dial gauge to zero. Photo 3 : Push turbine shaft to compressor side by hand. : Record the reading on dial gauge. :This reading is axial clearance. l ~ x i aclearance l

A

1

0.08 - 0.15 (rnrn)

caution

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

~~~~%r;;l9~!Ps>Xa;t~W~l : g,f+)LY-5gI>Y l,Yv4>&7%?%3*Yt-f&, 0,6Ei2Z$ao Photo 4 : 9-E'>u-9aI>Yb~Yvil~lEkZnl=#'

3-0

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Photo 5 :~ > Y I / ~ Y v ~ ~ l E T z m l : g+f+)LY-5miEEz%&4~6~

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QRadial clearance : Set the dial gauge pointer at the top end of compressor impeller and set dial gauge to Zero. Photo 4 : Push the turbine shaft upwards at compressor side by hand. :Record the reading on dial gauge. Photo 5 :Push the turbine shaft downwards at compressor side by hand. : Record the reading on dial gauge. :The total movement from upper position to lower position means radial clearance Allowable radial clearance is shown as follow

I Radial clearance

Initial clearance

allowable

0.45 - 0.6O(rnrn)

0.80(mm)

'

=

g~

Note

the measurement at least 3 times, and check ' 31)P~>xEt~W~ll;t;3~~B~~l)gL~;ie~~, Ti$ if Repeat 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 is observed 3 ~ ( 7(7002) 0 0 1 ) ~and semi-float bearing (7001).

M ~ ' ! S ~ ~ Z S U ~ ~ C _ ~ S I G B ?%L ~ - Cor L' ~ %the ~ .scoring or excessive wear when 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

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%%';a ( L O ) D a A L ) U I ; ~ : ~ L X % I = T = S ; E A % 13fiL\T ~ l / . 2 Y d > ~ 7 I $ ~ l l / ~ $RXl))RL\fY $~$, 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 Instructive points of overhaul

4.1.4 Mhk33%%a)$ESR3

fi9f!?%%mllZl $ k L T 4800 @[email protected]%I$%L b b h ' W h h ' f L L \ % P l t Z B h\I;a)IH3SQ ~~!lF%%ifi%LT) L\h\@3?LTX

Check if there is groove due to erosion on the surface of gas passage. Radial tip clearance at gas outlet part

Clearance R Measuring Position

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"2 R3

: Clearance gauge

Please +-f>Rt$~S7jt~.i-)~~)>Yjg${$~[z

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li

check and clean if carbon and sludge of lubricating accumulate of turbine ~ - ~ ~ > + ; . ~ ; ~ ~ ~ a ) ~ ~ . 2 ~ 4 ~ ~ oil f C t ~ h %mcaY Y -x%a>G$EH r4%&l]2B;ffli L lXS.F-6

For reference ; Standard dimension

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Usable

Unusable

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Carbons at shroud part of turbine housing and

l = l ; t ; h ) L - j 3 A ' c s / ( + 9 3 ~ $ g $ - ~ / t : ~ g ~ , turbine hwheel 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-"IcTTOlzflkLTR* (;EE{$II:Photo 6) Remove 1) @L\7 ~ Y ~ ~ ~ + X ~ L - / ~ I Z T T S1)I Z ~ - the carbon carefully by wire brush or scraper. $>g%kLrhCBkLl=%3fZlf%jE7K&6L\l;t:h-# turbine wheel in hot water or carbon removal solvents according to Chap. 4.1.4 Fig. 4. >@~~lII=~~L-CgzkL-C 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;%[email protected]< cleaning solvents in way of covering by wet rag

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that is soaked with solvents.

3) Photo 7, 8 l$r7'-7d?155TD3W%[email protected] TTT, Z f Z $9 2mm/l *hC30*$ZE%kh ;hT&L), T/H fj'[email protected]&Dh-*>&~?~* 5\~bflkLl:&PhT$0 L D & j % Z 5 E g @ M

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3) Photo 7, 8 show a sample of utilizing cleaning tools. This pneumatic tool that has bundled about 30 wires (2mmlpc) works effectively to remove carbon deposits on gas passage. Use it not to $;hQ%el;t;/\35>[email protected]+agEll~)4xhaL\ damage material of turbine housing itself. Also do not use it for cleaning of turbine wheel in order to 6, IiELT12FH LT

gine stop with

oking range

engine stop without cooli

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4.1.6

4.1.6 Accumulation of carbon deposits Oil leakage or bearing damage can be occurred by coking ~ E B I = A ~ I . ~ - ) L ~ T ; M ~ B ; B ~ I - + > ~ 'ofBlubrication ~ ~ ~ oil around the sealing section, because of heat soaking from turbine impeller after E~11~~iEh'[email protected]~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 carbon deposits are observed around it, remove EL-CL\6!ik%Tq0 deposits and do not damage the sealing surface. The seal ring must be renewed at every overhaul. Photo 11, 12 I&j%ELt=%UlTq, .

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In order to mitigate the coking phenomenon, idling I - - + l / y . ~ ~ ~ g + a r ; , f a~gkit;i~= ~tC~, 15 operation before engine stop is recommended for /n\P~71311a)T4FI)>~+LEt$~Ldb. (Fig.6 than minutes. PE) (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

,

$ ~ & f ; l = ? s 4 ~ > Y $ > y %15 ~ 'n'ra'fu % b ~ f ' ,pump

as soon as engine stopped and supply Lub. oil for more than 15 minutes. (Remark 1)

b B % & l : ~ M ~ f i i B % i & % L ~ T 2 ~(Sit!l \~ ) :it2

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Remark 1 Such priming pump may automatically or always be operated during standstill according to the engine 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 rnES.tYhfd3L1, AmmaL\% Y IIfZR%@H

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di.=.,8 s;h-r:L\a%#a>7;rzrgzifGL\L\< i.. $ L\

(3%1 1 % @ R< 75%Ll).

r/

Attach individual parts and large component modules carefully to suitable lifting devices, which are in technically, perfect condition and which possess adequate loading-bearing capacity. Do not stand under suspended loads (refer to chap. 1).

Table 2. Turbocharger

?l-g$3433,%*E~%Z!E,z,

I

Turbocharger complete with silencer

Table 3. Weight of assemble

SB Designation

7 i 7 ° L - y Y / \ r f Y i Y (?4 71--+f'!$) /

1 Compressor housing

(including Diffuser)

47 1) i Y / \ 9 Y i Y/Bearing housing 9 - F i/\ 9 Y i !f/Turbine housing 'ri E%Z/Silencer

I

Weight [kg] $958

I

J!#

84

$940 $933

I

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4.4

Disassembling the turbocharger -Refer to fig.8, Disassembling and assembling..

-

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Attach individual parts and large component modules carefully to suitable lifting devices that are in technically perfect condition and which possess adequate loading-bearing capacity. Do not stand under suspended loads. 4.4.1 Branch position Mark the turbocharger casing first so that it may be reassembled in the same location from which it is removed. 4.4.2

a/';;%&* kb(10003), @Pi

A

i2Ija%&(10004) E15x%T0 %%$4*(10001) EK?%'Tf.

Removing silencer (1000 1) -Refer to fig.8-1

a Remove hexagon bolts

(10003) and spring lock washer (10004). @ Remove silencer (10001).

S f !

Caution! Take cares no to damage the punched metal when dismantling silencer. 4.4.3

alfRr]4%[email protected](11006)~')4%% L 4;fkl 8-2 Eti t j ,

4.4.5

a!!%<

ai?fi&)L F- (11019),

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To @p-

i#!114~4~f~~(11006) 54PflT. @4x4$7ii>"l1008> & 4 9~%To

Removing turbine side foot (1 1006) -Refer to fig.8-2

a ~ e m o v ehexagon head bolts (11019) and spring lock washer (1 1020). @ Remove turbine side foot (11006). @ 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 100°C.

4.4.7

o;ifi$* I1 b(5003). C%[email protected]?(5004)E 4 9 f l T 0 @ j ? ~ f iL f~f;;%$'-lbb(5003) 2 /t\Q)T L kLfh' ICb 2 LTFFJtj, ?-11/7' 1 / - b (6001) k ? b @Q(1006)

E -%l:4xCKnT0 4.4.8 XjXb$i-(1002), X j X b ' 7IJj3' (7002)CT)@% L - 4\jH 8 - 1 @F,E-f$tjo 0 x 7 bhi-(1002) ~ (33/J01/5~94111)&4P%TO @>-1/7O 1/-bIf~f$)fl/kfi$11/b(5003) 2 *&$T L k Lf$'I b b 2 LTRl t l i l b q " 7'12~'( 7 0 0 2 ) G q ~ f l J,

To @ l i R bhi-(1002) ([email protected]) & 4 ? % T 0

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 spring lock washers (5004). @Using the removed 2 bolts, push up seal plate (6001) with sealing bush (1006).

4.4.8 Removing thrust collar (1002) and thrust bearing (7002) -Refer to fig.8-1 O ~ e m o v ethrust collar(1002) (compressor side). @Using the removed 2 bolts (5003) for seal plate, push up thrust bearing (7002). @ 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 housing (4001) by using plastic hammer. j l f ~ 9 h j 7 T 9 - k jll9>" ' >!I+ (4001)9\j31&$$ DPL]

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7 O

A Caution! The material of the bolts (4003) for turbine housing (4001) is heat resisting steel, therefore do not mix them with other bolts.

I;;@J$' kb(4003)1.2ifi$%~;t6CT)~, MO$'Jbb

L;tstlck5 I Z L T T S tl.

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

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When removing is difficult, tap heat shield (5005) by using plastic hammer.

% 7" i X f \ ~

4.4.12Removing seal ring (1009,1010) -Refer to fig.8-3

4.4.12.1 Removing seal ring (compressor side) (1010)

a Remove

ORYFK\L~>-ICJ' 1/-b(6001)J3~I;?dl%J1 ;U(1006) E4xflT0 @?ma 0
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