FINAL PLAN MET orio Hull Number : 129 Engine Number : 3920 Mitsubishi Exhaust Gas Turbocharger Model MET66SE Instruction Manual Serial Number_: 10087, 10088 oe MITSUBISHI HEAVY INDUSTRIES, LTD. T-EM66-0056wet Teenoo.ooo2 oe Contents Section 4 Turbocharger Basics Section 2 Operation Section 3 Maintenance Section 4 Disassembly and Re-assembly Section 5 Inspection of Components Section 6 Attached Diagrams and Tables Section 7 Cleaning Procedures for Compressor and Turbine during Operation ae MITSUBISHI HEAVY INDUSTRIES, LTB. o4 Instruction ManuatMET Tee100-0002 Contents Meanings of Cautionary Icons QN: Indicates items that should be carefully observed to prevent problems. (@ : Mdowtes that the ubocharger should not be touched due to high temperature. ‘ Instruction Manual A, MITSUBISHI HEAVY INDUSTRIES, LID. D2wer ‘TeEM00-0004 Section + MET Turbocharger Basics Section 1 MET Turbocharger Basics 4. Introduction 2. Turbocharger Structure 3, Proper Handling i Instruction Manual 24 mirsupisit HEAVY INDUSTRIES, LTD. 1mer Te-EM00-0004 Section} MET Turbocharger Basics Ne es 4, Introduction Because the turbocharger runs automatically as a result of the energy contained in exhaust gas from the engine, it does not usually require any special manipulation when the engine is operating normally. However, the ‘turbocherger plays an essential role in supplying combustion air to the engine, and itis therefore important to ‘maintain its performance in order to ensure the performance and relabilty of the engine itself. turbocharger is @ turbomachine with a high speed rotor. Consequently, because of the immense rotational eneray of the rotor during operation, Improper handling can result in substantial damage to the equipment, as well as the possibilty of human injury. This manual is intended to provide users with an understanding of the structure of the Mitsubishi MET turbocharger, appropriate maintenance procedures, and proper response in the rare event of malfunctioning. Accordingly, this menual should always be placed in a location where it can be easly accessed from the vicinity of the turbocharger. Also, al personnel concerned with the engine to which the turbocharger is afached should carefully read this, ‘manual and understand its content. If the content requires further clarification, please direct inquiries as follows, ‘quoling the serial number of the turbocharger in question. Technical Support: ‘Turbocharger Designing Section Marine Machinery Design Deparment Nagasaki Shipyards, Mitsubishi Heavy incites, Lt. Tol: ¥81-(0)95-821-2145 Fax: +81-(0)95-821-2279 E-mail: ATRR999@mhi.co.jo Instruction Manual 24 miTsumISHE HEAVY INDUSTRIES, LTD. 12mer Te-EM00-0004 2. Turbocharger Structure 2.1 Exhaust gas energy and air compression ‘Aturbocharger is @ device that utlizes the energy contained in exhaust gas from the engine in order to produce ‘compressed ait, which it raturns to the engine for use in the combustion of fuel. Thus, a turbocharger consists of @ turbine for the conversion of exhaust gas energy into motive force, together with an air compressor driven by this force. Exhaust gas released from the engine Is channeled to the turbocharger inlet casing (26, 27), and atter being expanded and accelerated by means of a nozzle ring (22), it comes into contact with the turbine blades (61). This serves to efficiently convert the energy into rotational motive force. A turbine blade wheel and compressor impeller are positioned at either end of the rotor, and the motive force of the turbine directly drives the compressor impeller. As the compressor impeller rotates, external air is channeled through the silencer (50) to the impeller (88), and is accelerated to obtain high velocity and pressure. The high level of energy contained in the air exiting the impeller Is recovered in the form of pressure as it passes through the diffuser (45). Then, after passing through the scroll (40, 44), ar having the required pressure and fiow volume is. sent to the engine. ‘The ratio consisting ofa) the energy obtained by pressurization of the surrounding air, divided by b) the energy lost as the exhaust gas passes through the turbocharger turbine, is known as the turbocharger efficiency, and this is a basic measure of turbocharger performance. Fouling and wear affecting the turbine and compressor are causes of reducad efficiency, and these factors can result in fallure to deliver air having the requisite pressure end flow volume tothe engine. It is therefore important to perform periodic maintenance of the turbocharger in order to maintain is performance. 2.2 Bearings and lubrication In operation, the rotor rotates at very high speeds, and the bearings that support it are specially designed to prevent the occurrence of harmful vibration. In particular, vibration is inhibited by the distinct internal shape journal bearings (70, 75) that suppor the mass ofthe roto, as wel as by the lubricant layer formed between tho journal bearing periphery and the housing, “The pressure of the exhaust gas and alr that act on the turbine blades and compressor impeller produce force on the rotor in the axial direction thrust), which is countered by the thrust bearings (71, 73), Because this thrust acts on the ‘compressor side during normal operation, the thrust bearing on the compressor side is larger than that on the turbine side. ‘The lubricant is externally supplied to the turbocharger at a specified pressure and temperature. Engines are normally equipped with instrumentation for the monitoring of turbocharger lubricant pressure and temperature, as well as apparatus for the protection of the turbocharger in the event of abnormalities. For more detailed information, please refer to the engine manual ‘The lubricant head tank is integrated with the upper part of the turbocharger bearing pedestal (30). This allows lubrication to continue for about 20 minutes in the event that the lubricant supply is cutoff for some reason andlor the engine stops. This lubrication is sufficient to prevent damage of the beatings in the time it takes for the rotor to come to a complete stop, 2.3 Lubricant and exhaust gas seals Cl labyrintns (88,87) are used to seal the lubricating oll so as to prevent leakage from the turbocharger, while a gas labyrinth (24) is used to seel the exhaust gas within the turbine discs. Sealing airis also channeled from the scroll to prevent oll and gas leakage from inside the turbine discs, During periods of low load on the engine, the scroll can be subject to negative pressure due to the suction of arfrom the engine side. This creates nagative pressure in the alr channels for the sealing air noted above, and a vacuum breaker is therefore installed along the sealing alr channel in order to prevent oil fram being sucked out. : Instruction Manuat 24 MITSUBISHI HEAVY INDUSTRIES, LTD. 13MET TeENOO-0004 Section + MET Turbocharger Basics 3. Proper Handling 3.1 Turbocharger modification and changes to specifications ‘The turbocharger to which this manual refere has beon set so as to deliver optimal performance in conjunction with the engine to which itis attached. Accordingly, any modification or changes to specifications may negatively affect the performance of not only the turbocharger, but also the performance and reliablity of the engine itself. For this reason, we strongly advise against such action without the approval of Mil, If and when screws from the turbocharger main unit are used to fasten other components, or when other components are welded to the ‘urbecharger main unt, please be sure to consult with MH fist No parts or components other than genuine parts supplied by MHI should ever be used with the turbocharger. 3.2 Disassembly and re-assembly No special training is requited for persons who have experience with the disassembly of general large-scale ‘equipment. For such persons, careful reading of this manual should be sufficient o enable disassembly and re- assembly ofthe turbocharger. However, the disassembly and re-assembly processes require hazardous operations ‘such as the suspension of heavy objects. Operators should have the skills and knowledge required to perform these operations safely, and operations must be conducted under appropriate safety supervision. MHI assumes no responsiolity for injuries and/or damage to the turbocharger and peripheral equipment in the event of accidents occurring during turbocharger disassembly and re-assembly 2.3 Alowable turbocharger temperature and speed ‘he slowablerbocerge emperors and speed (pm) ae ted on he meh namepate (66 Fig 1-1). These (anes oe na exceed dain normal peratn. However, para case required uncer re ofowing A Sreamsarcos, noe alowabe values mey be exceeded, pouty rating m serous damage or acids {Occurence of tbecaier surging (phenomenon whist reverse oof arm the compressor i serompanled by htembet oud nls) 2. Leakage or air andlor exhaust gas crue] yA wee me MITSUBISHI EXHAUST -GAS TURBOCHARGER TYPE Cs SPE ney wi com see Ton MAX. CONT.GAS TEMP [_—— c MITSUBISHI 8.Excessive exhaust gas energy due to regular combustion in the engine (e.g. fire in scavenge air= of exhaust gas receiver) 0-0-0-00.0 Fig. 1-1 Turbocharger main nameplate 3.4 Service and repairs ‘As noted in the Attachments (Section 6, Subsection 7), MHI-authorized turbocharger service companies are located throughout the world. These organizations include engineers who possess the skills and knowledge required for the ‘maintenance of the turbocharger described in this manual. If disassembly and re-assembly should pose any diffculies, these service companies can also be called upon. i‘ Instruction Manual af mrTsUBISHI HEAVY INDUSTRIES, LTD. +4MET “Tz-€100-0002 Section 2 Operation Section 2 Operation 4. Safety During Operation 2. Inspection Before and After Startup Inetruction Manual fx miTSUBISHI HEAVY INDUSTRIES, LTD. a4Mer Te-€Mo0-D002 Section 2 Operation 4, Safety During Operation The rotational speed of the compressor impeller and turbine wheel of the turbocharger exceed the speed of sound, and the associated energy is very high. Accordingly, standing inthe area indicated below should be avoided unless there is a specific reason to do so. When approaching the turbocharger to perform measurements, inspection, etc, these actions should be completed in the minimum possible time, 24-1-0.0-0-000 Also, tn stance rit por eve inlarg ares far nthe evento sudden suing, there Is a possbity cme reverse fom of ighpresste a om he silencer. n such cases, promi tothe lence oul rest inthe foes efbaoncs end malo nur: prialr cautions thus reqied, When approaching the ubocharger, care shoul be taken tat pene end alher smal beds sbout one's person are rot suckedin, Such abject should ther note cared, o leafed erly using ong or cord co aso provent ingestion io the ubecharger “he nol levelin th vy ofthe turbocharger I igh, and earphgs or other appropri protective gear shoud be used wen approaching, ‘The rbocharger aco and the turbine ie casing are hl, and shout never be touched without protection Te turbocharger pars remain hot period ater the engine hes been stopped hence cate shold also be tken here iis posse fo various reasons thal exhaust ge could ek rom tho exhaust gs piping connected othe turbocharger or fom the turbocharger main unt. In euch eos, ter sa ik that th ubocherger vould Suck tohour ges ough the lence, wih th esl tha neuficnt ak would be supped oe engine, an hat ie {crperatire of he compressor Impeller wuld se, ths leadng to damage of comoressor wee! materia and Uimately breakage of he compressor vied and lhe part of ubechrge. Alo the breet'ng of exhaust fumes fora prolonged period may cause helt problems Accordingly, if the smell of exhaust gas is noticed in the vicinity of the turbocharger, the origin of the leak should be contmed ant the agin stopped a eon e pose fo enable he epproprite response In the event of lubricating oil leakage from the lubricant tubing connected to the turbocharger, particularly in the ZX sig pressure nit tabing, there isa sk ofignion and fire cue tothe decharge of bricant, Wsuch leskage oocu, the engine soul be slorped inrmeriatey end caret atone taken to ebminat th leakage Instruction Manual atx MITSUBISHI HEAVY INDUSTRIES, LTD. 22Mer ‘Te-E100-0002 Section 2 Operation 2. Inspection Before and After Startup aA 2.4 Before startup Be sure to complete the following inspection and other listed steps. Inspection item Inspettion content Notes Librcant niet ot | Ol pressure ehowing on the engine side gauge [+ [pees aoe ees Sevteia2 Ludbeantiniet oi | Oil temperature showing on the engine side 2 [temperature gauge within the spectied value? poor 22 3 | Airmer ‘Any damage to air fier or obvious blockage? | See Page 5-11 Turbocharger aoe | ae Any Ollleakage? See Page 62 Lubricant niet and 2 ee Ary Oileakage? See Page 62 6 | Heatresisiant lagging | Any peeing or other damage? 7 | Lotvicant ter Any abnormal sen ferential pressure? Ay 22 aor startup Inspection item Inspestion content Notes Liubcantiniet ot | Of pressure showing on the engine side gauge 1 | pressure within the specified value? ceoraez2 Litbcantiniet ot | Oil temperature showing on the engine side : 2 | tomperature gauge wihin the spectied value? sea Bihaust gas, air ee a |S Any exhaust ga: Turbocharger 4 | Turbochar Any Oil eakage? See Page 62 Turbocharger main : 5 [tw Any abnormal vibration or noise? @ | exaust gas ‘Any significant diference compared 10 past temperature ‘measurement valies, at simlar engin load 7 7 | Scavenging air ‘Any significant ference compared 10 past prescure measurement values, at similar engine oad 7 cupochargerm | APY significant diference compared to past 8 | Turbochargers | measurement values, at simlar engin load 7 9 | Beating pedestal side | ls ir blowing normaly? surfaces Dees bown ar contain ol mist? Instruction Rtanual A mirrsuBisHl HEAVY INDUSTRIES, LTD. 23Mer ‘TzEM00.0002 Section 2 Operation en TEEEIEEEEEEnaI EEE ‘Table 2.2 Utilization standards for lubricating oil Min. Standard Wax. Tubricant inlet ofl pressure MPa 0.06 0.08~0.15 045 (At turbocharger center height) kg/cm? 06 06~15 1.5 bar 06 06~ 1.45 1.45 Lubricant inet oil temperature, “C B 35~50 35 Lubricant outlet ol temperature," = = 85 (Oi supply time following engine stop, min. 30 _ = 2240.00.00 Note: Please be sure to use lubricating oil having properties that satisfy the concitions shown in the ‘ollowing table (Table 2-3) Table 2-3 Lubricating oil properties Span Renae Spon eran ole a Cigieal [ TabnesP [Eine ci | Turbne a Vistbsly ede SREP evens 100 | Sa#20 30,40 —| Voss, on ae aoe Pants [a 10 | Sey aN | ODsINey viscosity yore | mms | 5.6~163 = ossiver<1alv | 0.95IVNa15 >N=I5 Saga © 26 = =i 0 ‘ir conte [se Sor [008 =02 =04 Teaihse : ans 7 i a O25 can si akon Toa mS (5) sttach anu tothe end ofthe rotor shaft and iit using. sto.80 not sip, (Pi ire, Also, do not use an eysbolton the end of sha. 4-10-1-66-0-0-00.0 Weight Tyee | (Arpron) ka 33_| 130 65 _|_230 71 _| 300 33 [ 410 4-10-3.0-BE1-0.000 410-4-0-EE110-00.0 Fig, 410 Procedure for removing the rotor eee i Instruction Manual a4 mrrsupisHi HEAVY INDUSTRIES, LTD. 48METBSSE ‘T=EMB6-0004 Section 4 Disassembly and Re-assembly 1.8 Removing the bearings and labyrinths (1) Turbine side journal bearings 75, gas fabyrinth 2, turbine side oll labyrinth 35, and slinger 745 {tis not normally necessary to remove gas labyrinth 24, but, in case removal s required, frst remove the restraining bolts 241, end then serew the bolt into the threaded hole to slowly liftoff and remove the labyrinth. ‘To remove the turbine side oil labyrinth, frst remove restraining bolt 952, Using liting screw 7-24, lit off the oll labyrinth. After removing the turbine side labyrinth and stinger, it will be possible to easily remove the turbine side journal ‘bearings using threaded bar 7-24 411-2-66-0-0-000 111-3-58-00.000 Fig. 4-11. Procedure for removing the turbine side journal bearings, ol labyrinth, and slinger Instruction Manual Se MITSUBISHI HEAVY INDUSTRIES, LTD. 4-10METeSSE T2£M8s-0004 Section 4 Disassembly and Re-essembly (2) Turbine side thrust bearings 71 and compressor side journal bearings 70 Use hexagonal headed spanner (hex key, Allen wrench) 730 to remove hex bolt 713, and then remove the turbine side thrust bearings by hand. “The compressor side journal bearings can be removed using threaded bar 7-21 412-4-5678-0.6-00-0 Fig. 4-12 Procedure for removing the turbine side thrust bearings and the compressor side journal bearings Instruction Manual 4s mirsusisit HEAVY INDUSTRIES, LTD. antMeTeESE: Te-EM55-0006 Section Disassembly and Re-essambly SER (3) Compressor sido thrust bearings 73 and compressor side oll labyrinth 37 Use hexagonal headed spanner (hex key, Allen wrench} T-30 to remove hex bolt 733, and then screw the same bolt 738 into the threaded hole in the compressor side thrust bearings. Liftoff the beerings. In some cases, adjustment liner 771 will also be attached. After removing the compressor side thrust bearing, turn over the support to unbolt, fx securely the puller T-45 with the bolt 7-12 end push up the compressor side oll labyrinth using starting bolt T-24. 4-13-1-56-0E6110-00-0 \ \ 2 2%. OL LABYRINTH (B) THRUST BRG (8) Fig. 4-13 Procedure for removing the compressor side thrust bearings and oll labyrinth rn Instruction Manual 24s mITSUBISH HEAVY INDUSTRIES, LTD. 412METESSE TeEM58.0004 Seciion4 Disassembiy and Re-assembly 4.9 Removing the nozzle and gas outlet guide Remove restraining bolts 225, and screw bolt 225 into the threaded hole for iting located in the inner ring of the nozzle 22. If bolt 226 proves difficult to loosen, spray with commercially avaliable penetrant, or gently heat the Inner Ting of the nozzie. The nozzle bolts are made of stainless steel. Please be sure to store them so that they can be distinguished from other similar items. Itis not normally necessary to remove gas outlet guide 23 for cleaning. However, in case of replacement due to ‘wear, etc, remove restraining bolts 234, and it off. 4-14-2-0-DE-D-00-0 Fig. 4-14 Procedure for removing the nozzle and gas outlet guide Instruction Manual 4, mirsusisil HEAVY INDUSTRIES, LTD. 413“T2-EM66-0004 Mevesse Section 4 Disassembly and Ri Pazsty S SPUNE mh (B) sewn \ BOLT BOLT 4 T \ \ [anti seizure agent| @®~a@ Eg | eA Lubricant @ Bee ® Bona FER SHO Fig, 4-15 Locations for application of anti-seizure agent Instruction Manual Ae MITSUBISHI HEAVY INDUSTRIES, LTD. 414TeEMB6-0004 2, Re-assembly Re The order of re-assembly is essentially the reverse ofthat for disassembly, but there are points deserving of caution. Mistakes in re-assembly, use of components other than genuine MHI parts, and use of wom parts can cause not only loss of turbocharger performance, but also accidents leading to human injury. AS parts inspection procedures are listed in Section 3, please use this section as a reference in determining whether parts can be reused of not. Before starting re-ascembly work, please be sure to read this subsection carefully and understand its content, In cease any point(s) is/are unclear, suspend work and contact MHI or an authorized service company for confirmation. 3F fo Section 3 for parts inspection procedures following disassembly. 2.1 Replacement of worn parts Replace all tongued washers, O-rings, gaskets, lock plates, and stainless steel wires with new ones. Do NOT reuse these parts, 2.2 Tightening the nozzle restraining bolt Because noze resiralning bolt 225 Is easly subject to seizure, it should be coated with anti-seizure agent, and care should be exercised so as not to overtighten it. 2.3 Coating with anti-seizure agent Coat the locations indicated in Fig. 4-15 with antt-seizure agent. The Items specified inthe folowing table are suitable. Anti-seizure agent Coating location MOLYKOTE 1102 GASCOCK GREASE ERH MOLYKOTE 1000 PASTE AB.C.D,G FiSTO00000 Instruction Manual 4 MITSUBISHI HEAVY INDUSTRIES, LTD, 4416TeEM6s-0004 2.4 Bearing re-assembly Prior to inserting any of the bearings in the turbocharger, use compressed air, etc. after cleaning to completely remove all drt and other foreign matter from the metal surfaces and lubricant grooves. Before inserting any of the bearings, be sure to lighty coat them with lubricant, When inserting bearings, use clean bare hands; do not use gloves, etc. 2.5 Inserting the rotor After installing the compressor side journal bearings, turbine side thrust bearings, turbine side journal bearings, turbine side singer, and turbine side oil labyrinth, insert the rotor shaft ino the pedestal. At this ime, make sure that the rotor shaft protection tube is stil attached, Completely cemove all dirt and other foreign matter from the rotor i a wt ily coat: ings will pass {fom A® fhe wotetion ube oar f i Exercise sufficient care so as to avoid damage to the turbine side oil labyrinth fins when inserting the rotor, Confirm thatthe rotor protection tube is free from all dirt and foreign matter. Any damage can cause damage to the journal bearings, rendering them unusable. 2.6 Inserting the support Alter inserting the rotor shaft into the pedestal, remove the rotor shaft protection tube. Insert the rotor shaft through the thrust collar, and attach the support. Peete aa ee eee eee s Instruction Manual 24 miTsusISHI HEAVY INDUSTRIES, LTD, 4aaTeT eSE ‘Te-€M6-0004 Secilon 4 Disessembly and Re-assombly S40 7-9 / Diol gauge 4-17-1-0-6-0-00-0 Fig. 4-17 Procedure for measuring rotor deflection Instruction Manual 24 MITSUBISHI HEAVY INDUSTRIES, LTD. 418METSESE ‘TeEMGs-0004 ‘Section 4 Disassembly and Re-assembly 2.8 Fastening the impeller Ifthe impeller is insufficiently secured, the load on the claw clutch increases, which can cause damage to the impeller, Please be sure to fasten the impeller in accordance with this subsection. When the engagement between the impeller and the sleeve has been confirmed, and the impeller has baen pushed all the way in by hand, screw nut 67 onto the end of the shaf, also by hand. Next, soraw the hydraulic jack into the end of the shaft. Hore conf ha he impli trom teperture. Tghening at high emperature may result in loosening during operation Raise the hyéraule pressure tothe designated level, and tm nut 6 using ber 7-2 unl itstops. Then, arf AX, oucing tne hydraulic pressure, raise the pressure again to the designated evel. Check whether the nut can be Lumed further. For he ipeliUehtening torque, please refer to below abe occur tho distance between the edge ofrut 7 andthe end ofthe sha using slide (vere capers ora depth gauge, and compare the value with that obtained before disassembly. If the difference is 0.1mm or greater, please consult with MHI 2.8 Rotor shat etecton ‘or fetening We pote un the oir shatcoute-cacsby hand and confi et roast and fut any crcl nte Nox. mess te defecten the endo he rot shat sng a dl gage, Defleston o 010mm or more Inca te heen efouen mar ene contact eae oe nto eo bt ener andere AM Sat ceuingieiaton ote oa shat. Remote the npr ga, and cont fa above ned conse suraces, Remesnire the deflecon a he on eh tr sat pio fang the peter sD SE SEIl 33.3 [MPa] 59.8 [MPa] or MEE 340 [kglom’] 640 (kalo?) 34.3 [MPa] 39.2 [MPa] ae Meta 360 [kg/cm] 400 [kal aa 56.8 [MPa 62.8 MPa] 50.0 [Pa] 600 fxgicm*) 640 fkglem*] 510 Ikolom’) — 58.8 [MPal 83.7 MPa] 51.0 [MPa] 600 [kg/om?] 850 [kalom*} 520 [kglcm’ Rae 53.9 [MPa] ‘57.8[MPe] eke 550 [kg/cm] 590 [ko/om™] 38.6 (Pal 65.7 [MPa] 62.9 [MPa] METes zoo eae ero eon ab gon leet 68.6 [MPa] fans MET9O oe 417:2.00-0-000 a Instruction Manual (MITSUBISHI HEAVY INDUSTRIES, LTD. 449MeTeEsE TeEM66-0004 Section4 Disassembly and Re-assembly 2.10 Measuring the thrust clearance of the rotor ‘After confirming the shaft deflection, apply the dial gauge in the axial direction and measure the axial movement of Dx 321 wien posed by hand te trust eeranoe Confirm that the clearance is the same as before, disassembly. The thrust clearance should normally be in the range of 0.26~0.36mm. In the event that the value is outside this range, remiove the impeller, and confirm that there is no foreign mater on the contact surfaces of the impeller, sleave, thrust collar, and/or rotor shaft. Please consult with MHI in cases where the thrust clearance value cannot be obtained in the designated range. ca Thrust cleorance ‘ SANT SSH 1) I ba .26~0.36 i ii jie F-¥ Dial gouge baka 4181-0-0.6-00.0 Fig. 4-18 Procedure for measuring the thrust clearance Measuring the respective clearances ler installing ing. impeller q nd the turbine blade tip clear Refer to the ci ie in Sector So valu Instruction Manual 4a MITSUBISHI HEAVY INDUSTRIES, LTD. 4-20Mer Section § Parts inspestion and Cleaning ‘TeEMo0-o008 Section 5 Parts Inspection and Cleaning 1. Bearings 2. Rotor Shaft 3. Compressor Impeller 4. Pedestal-related 5. Turbine Blades 6, Nozzle 7. Air Filter fs MITSUBISHI HEAVY INDUSTRIES, LTD. 54 Instruction manual= TeEM00-0008, Secon § Parts Inspection and Cleaning 4, Bearings Bearing wear proceeds as the bearing metal is abraded by foreign matter in the lubricating oll. Hardly any bearing wear occurs when the tubricant layer is extremely thick compared to the size of the foreign particles, but wear proceeds quickly when the particle size is about the same as the lubricant fim. In cases where system oil rom the engine is used as the lubricant forthe turbocharger, 2 suitable lubricant filter is installed on the engine side to remiove damaging parties. However, smaller particles cannot be completely removed, and these induce bearing weer. ‘Accordingly, maintaining the engine lubricating oil in good condition is important from the standpoint of the turbocharger bearings. For more detalled information, please refer to the engine manual 4.1 Thrust bearings “Thrust bearings are of the tapered land type, consisting of a tapered part and a fle parl. Oil is pulled into the ‘wedge-shaped opening formed between the thrust collar and the tapered part of the bearings by means of the rotating action of the thrust collar, thus creating oll pressure that supports the thrust load. When the thrust bearings become worn, the ratio occupied by the fet part increases. “The limit of servi life for thrust bearings Is 2s follows: Length of tapered part: Length of fat part 4 (Compressor side, See figure below) = ts (Turbine side, See figure below) However, even ifthe ratio has not yet reached 2:1 [compressor side) or 1:1(turbine side), the bearings should be replaced when itis anticipated that the ration will raach 2:1(compressor side) or 1:1(turbine side) before the next Inspection. Regarding the inspection procedure for the ratio of the tapered part to the fiat pat, please refer to Fig. -1 Rotor Turning Direction ea Rotor Turning Direction The time of — SS Replacement ey oe service life (Compressor side) (Turbine side) 511000010 Instruction Manual as MITSUBISHI HEAVY INDUSTRIES, LTD. 52mer e-EM00-0008 Section 5 Pars inspection and Cleaning Ty] ——~T 3 7 Calor the base late | Tighty piace the colored [Rotate the base pate in |” Remove the baseplate, lightly ané everly using | side against the metal | one direction so that the | &1td confirm the transfer a oe ioeedtie best : a of the red ink in order to 2 red-ead paint face ofthe bearings. | redlead paint contacts | Siwerod int in over the thrust bearings. roplecomoat! S Direction of base plate rotation Tapered land Flatland Tapered land Flat land Sr 20-0001-0 Fig. 5-1 Inspection procedure for the tapered:flat part ratio. {In the event thata long, deep scratch of 20mm in length or greater are evident on the thrust beating metal surface, or if multiple deep scratches add up to @ total length of 50mm or more, the thrust bearings should be replaced with new ones, ‘Any visible exfoliation or cracking of the thrust bearing metal surface also indicates the need for replacement, ‘ Instruction Manuat 2x mrrsuBIsH! HEAVY INDUSTRIES, LTD. 53er Te-EMg0.0008 Seaton 6 Parts inspection end Cleaning 2.2 Journal bearings After removing the rotor, insert it through the journal bearings and, using a dial gauge, measure the clearance between the inner surface of the journal bearings end the rotor shaft, with the upper side ofthe inner surface against the shat. Compare the measured results with the clearance standard table presented in Section 6, Also, be sure not to afk the dial gauge to the rotor when performing the measurement (as magnetic force will remain on the rotor shaf). Ifthe clearance ie greater than the allowable value, it will be necessary to confirm whether the rotor shaft andlor the journal bearings have become worn. Please refer to Subsection 2 below in determining whether the rotor shaft has become worn, If tis confirmed that the rotor shail is not worn, and the clearance is greater than the allowable value, the journal bearings should be replaced with new ones. a A, \ 0-0-000 Fig. &2 Procedure for measuring the clearance between the journal bearings and the roter shaft, {Api for locking is located on the journal bearings. Ifthe pin diameter has been worn by 20% or more, or If is damaged, the journal bearings should be replaced with new ones. 2vgey Knock pin Sliding surface 53-1-0-0-0000 Fig. 53 Joumal bearing lock pin ‘ Instruction Manual 2. MITSUBISHI HEAVY INDUSTRIES, LTD. 54