construction and working

(1)-It consists of a mixed flow turbine and radial flow turbine assembled as a single
unit.
(2)-Exhaust gas flows through the turbine housing and enter the turbine wheel and
provide the rotating torque to the turbine shaft.
(3)-The compressor wheel fitted to the turbine shaft which recieves the rotating torque
and induces air through the silencer and delivers it to the cylinder after compression.
(4)-Seal plate and seal ring are provided so that air and oil are not leaked.
(5)-Since thrust force is constantly applied to the turbine shaft the thrust bearing is
provided to prevent move of the shaft due to thrust force.
(6)-A dual oil film is formed on the internal and external faces of the bearing the
bearing bush rotates and the sliding speed of each bearing face is lower than the
turbine shaft speed resulting in an increase in dynamic stabilisation.
OPERATION
PREPARATION FOR OPERATION
(1)-Before starting the engine operate lub. oil priming pump and circulate lub oil in the
turbocharger. set lub oil pressure to (.05-.1)Mpa.
(2)-Circulate cooling water to the engine and confirm drain from air vent.
DURING OPERATION
(1)-Check for leakage from exhaust pipes,air pipes,lub oil pipes and cooling water
pipes.
(2)-Be sure lub oil pressure of the turbocharger is between (.2-.5) Mpa.
(3)-Record all indicator values especially pressure and temperature of boost air and
exhaust gas at turbocharger inlet and outlet as these affect the performance of the
turbocharger.
AFTER OPERATION
(1)-Before stopping the engine start priming pump and run it for atleast 15 mins. to cool
down.
(2)-As the lub oil of the engine and turbocharger is same periodically conduct sampling
and clean lub oil filter or replace it. The lub oil should have quality acc. to the
manufacturers manual.
COOLING WATER QUALITY CONTROL
(1)-Cooling water to the turbocharger is supplied from the engine.
DAILY INSPECTION
WATER WASHING OF COMPRESSOR
(1)-Dirt accumulation depends upon the operation condition of the engine which affects
the engine performance.This can be prevented by periodic water washing (atleast
once a week)
(2)-Operate the engine at 75% load or more and after water washing run the engine at
the same load for more than 15 mins.
(3)-Use only the specified cleaning liquid. Dont use flammable liquid such as light oil.
(4)-Use the cleaning unit provided with the engine for compressor washing.
(5)-Pour specified amount of fresh water or cleaning liquid in the syringe
(6)-Connect the syringe socket to the filling pipe connected to the turbocharger inlet .
(7)-Fully open drain cock of air inlet duct.

(8)-Press the syringe and inject all the cleaning liquid in 4 to 10 secs,.In 3 -5 mins after
injecting cleaning liquid inject the same amount of fresh water
(9)-If the pressure of intake air and temp. of exhaust gas dont change before and after
the water washing, perform the water washing again after 10 mins.. If there is no effect
of repeated washing conduct overhaul.
WATER WASHING OF TURBINE BLADES
(1)-Sometimes turbine blades get damaged because of carbon accumulation it is
efficient to conduct water washing to reduce the accumulation, so perform water
washing at the turbine blades.
(2)-Connect gauge board with rubber hose
(3)-Connect water feed hose with the gauge board.
(4)-Do not use cooling water at the engine as cleaning liquid, as it may contain some
additives which may cause bad effects on the turbocharger.
(5)-Open the pressure adjusting valve to lead water to nozzle and hose and adjust the
pressure to about 0.05Mpa
(6)-Open the drain cock, loosen lock nut and fully open the nozzle(without fully opening
the nozzle, water leakage will occur
(7)-Adjust the pressure adjusting valve between (.05-.08)Mpa at pressure gauge
(8)-During injecting water always check for access of the water and clogging of the
drain pipe .
(9)-During the water washing if there is abnormal sound in the turbocharger, decrease
water pressure until the sound drops or stop the water washing
(10)-Continue injecting water for 5-7mins. Even if there is no drainage do not continue
injecting water for more than 7mins.
(11)-When finishing injection of wate, close the nozzle and be sure that there is no
drainage and close the drain cock
(12)-After washing remove the hose
(13)-After the water washing, operate the engine at same or higher load for more than
10mins.
(14)-Conduct water washing every 250hrs, if the turbocharger gets more dirt shorten
the washing interval
(15)-Adjust and keep the engine mode so as to keep the exhaust gas temperature at
turbocharger inlet to be 300 to 350 deg.C, keep the condition for about 20mins and
then carry out water washing.
(16)-To drive the turbocharger surely after the water washing keep operating the
engine with the load.
PERIODIC INPECTION(1200HRS)
(1)-Remove silencer and rotate compresser wheel by hand, if the wheel rotates lightly
turbine shaft is in good condition, if there is any unnecessary sound conduct the
inspection.
PERIODIC INSPECTION(2400HRS)
(1)-Measure axial and radial clearance of turbine shaft, be sure measured values are
in allowable limits.
(2)-Regarding assembly and disassembly of turbine shaft refer to the 4800hrs periodic
inspection.

PERIODIC INSPECTION(4800HRS)
*DISMANTLING*
(1)-At first prepare tools and spare parts, grease and cleaner
(2)-For dismantling wear helmet, earplugs, gloves and safety shoes.
(3)-Cool down the engine sufficiently
(4)-Start lube oil priming pump and drain jacket cooling water.
(5)-Mark match marks on exhaust outlet, boost air inlet and tubine sidefoot.
(6)-Remove filling pipe for blower washing
(7)-Remove silencer, rotate turbine rotor by hand and check rotation condition.
(8)-Remove anti splashing tape, remove lube oil pipe, cover lube oil inlet with tape.
(9)-Remove the inlet pipe for cooling water and cover them with tape.
(10)-Remove lube oil outlet pipe ad cover its outlet with tape.
(11)-Remove heat insulation around the casing.
(12)-Remove outlet pipe for cooling water and cover with tape.
(13)-Remove thermometer at exhaust inlet.
(14)-Remove heat insulation around exhaust inlet pipe.
(15)-Remove bolts on exhaust inlet pipe.
(16)-Remove bolts fixed on boost air outlet pipe
(17)-Remove bolts from exhaust outlet pipe.
(18)-Remove bolts fixing the turbocharger.
(19)-Suspend the turbocharger with wire rope, take care not to damage the parts
around the turbocharger and place the turbocharger on the worktable.
*DISASSEMBLY*
(1)-Fix turbocharger on work table.
(2)-Measure clearance between turbine and turbine housing.
(3)-Use thickness gauges at once and measure clearance in vertical and horizontal
direction record the measured value on prescribed form.
(4)-Before moving to compressor housing mark the match mark.
(5)-Stand compressor housing, remove bolts and compressor side clamps.
(6)-Suspend compressor housing using wire rope.
(7)-Remove compressor housing carefully, do not damage the compressor impeller. If
it is hard to remove tap it with plastic hammer
(8)-Remove the o-ring fitting on outside circumference of bearing housing. Do not
remove diffuser except the case of inspection and replacement.
(9)-Fix the turbocharger on worktable, measure axia clearance with dial gauge, hold
both ends of rotor shaft , so as not to rotate. Move the shaft from side to side and
measure axial clearance, record the measured value on prescribed form.
(10)-Set the dial gauge again to measure the radial clearance.
(11)-Hold both the ends of rotor shaft and move the shaft upward and downward.
(12)-Check match marks on compressor impeller and shaft end hexagonal nut.
(13)-Fit up turbine housing with turbine locking tool.
(14)-Loose shaft end hexagonal nut on compressor side as the nut is left hand screw,
rotate it in clockwise direction.
(15)Do not remove the nut completely.
(16) Mark Match marks on turbine housing and bearing housing.
(17)-Place turbine housing on the work table.

(18)Remove bolts and turbine side clamps.

(19)-Lift bearing housing upto 5mm from the worktable by using two wire ropes, incase
the housing doesnt turn tap the housing with a plastic hammer.
(20)-Some bolts cannot be removed as the flanges of the housing interfere with the
bolts, in that case turn the housing to where it does not interfere with the bolts and then
remove the bolts.
(21)-extract turbine housing carefully.
(22)-Remove metal seal gasket.
(23)-Fix bearing housing in vice, putting wood between the contact surfaces, it will
make the bearing housing more stable.
(24)-Turn shaft end hexagonal nut clockwise and remove it
(25)-Hold turbine rotor by hand and remove compressor impeller. If it is hard to remove
compressor impeller heat it with industrial drier or other device.
(26)-Do not heat the impeller upto 100deg.c
(27)-Do not strike compressor impeller with hammer, it can cause bending of impeller.
(28) Remove bolts of seal plate, use two removed bolts as jack bolts, jack up seal plate
by screwing the jack bolts and extract the plate, remove seal plate o-ring and also
remove sealing bush from seal plate.
(29)-Check movement of seal ring on sealing bush. Remove seal ring by using seal
ring pliers.
(30)-Remove thrust collar of the floating journal bearing. Mark identification mark on
the collar.
(31)-To extract thrust bearing use bolts removed from the seal plate as jack bolts after
the thrust bearing is removed, remove the distance piece, remove thrust collar on
turbine side and put an identification mark.
(32)Wrap the turbine shaft end with tape to protect floating journal bearing and thread.
(33)Remove the turbine shaft carefully and take care that the floating journal is not
damaged.
(34)-Check the turbine shaft and the movement of seal ring.
(35)-To remove inner seal ring use seal ring pliers.
(36)-Remove heat shield, if hard to remove tap it with plastic hammer.
(37)-Remove outer snap ring on compressor side by using snap ring plier.
(38)-Remove floating journal bearing on compressor side, check its surfaces and mark
it with an identification mark.
(39)-Remove inner snap ring.
(40)-Remove outer snap ring on turbine side.
(41)-Remove floating journal bearing o turbine side, check its surfaces and mark it with
an identification mark.
(42)-Remove inner snap ring.
CLEANING
(1)-Prepare tools and wear protective gears.
(2)-Parts to be cleaned are:
Heat shield
Turbine shaft
Turbine housing

(3)-As the turbine impeller and shaft are soaked in cleaning agent cover the shaft part
with protective equipment.
(4)-Prepare a stand so as not to soak the shaft part in the cleaning agent.
(5)-Prepare a cleaning bath and put turbine housing an heat shield in it.
(6)-Put turbine shaft into the bath, be sure not to soak the shaft part.
(7)-Wait for some time till the cleaning agent soaks the carbon deposit.
(8)-When the agent penetrates into carbon deposit, use a brush and remove the
deposits, be sure not to splash cleaning agent to shaft part.
(9)-Remove the deposit on heat shield by using brush.
(10)-Remove the deposits on turbine housing by using wire brush.
(11)-After this process wash the parts and blow them with air.
(12)-Cover the mount part of the heat shield with soft cloth and take some time for the
agent to penetrate the deposit.
(13)-When agent penetrates the carbon deposit remove it using brush.
Parts to be cleaned with flushing oil are:
Compressor impeller
Seal plate
Sealing bush
Thrust bearing
Distance piece
Bearing housing