IHI RH183, RH183L User Manual

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EXHAUST GAS TURBOCHARGER

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T Y P E R H 1 8 3 / 1 8 3 L / 2 0 3

(Version : Y )

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Bearing housing with foot

(Semi-f loat bearing)

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Instruct ions

for operation and maintenance

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Ishikawajima-Harima Heavy Industries Co., Ltd.

TOKYO JAPAN

RH183FSYAR3

[phone]

[phone]

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 [phone]-5986
	03-5950-0491(24hrs)	[phone](24hrs)
FAX	03-5611-5997	FAX [phone]
		East Japan Service Station
		22-1, Honjo 1-chome, Sumida-ku,
		Tokyo 130-0004,JAPAN
TEL [phone]		TEL [phone]
FAX	03-5619-5022	FAX [phone]

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TEL [phone] FAX [phone]

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3-9-36-303

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FAX [phone]

Kobe

West Japan Service Dept.

West Japan Service Station

3-2, Wakihamakaigandori 2-chome,

Chuo-ku, Kobe-shi, Hyogo 651-0073,

JAPAN

(West Japan Service Dept.)

TEL [phone] FAX [phone]

(West Japan Service Station) TEL [phone] FAX [phone]

Imabari Office

3-9-36-303,Higashimura, Imabari-shi,

Ehime 799-1506, JAPAN

TEL [phone]

FAX [phone]

TEL [phone] FAX [phone]

Kyushu Service Station

1418, Aza-Daima, Ueki, Suemachi,

Kasuya-gun, Fukuoka 811-2112,

JAPAN

TEL

FAX

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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,	As stamped on the rating
Specification	plate of turbocharger
	(Refer to Fig. l,sect.2-2)
P a r t number
and designation	As per Fig.2bect.2-3) and
Quantity	Iparts 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.

C o n t e n t 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

4.1Cleaning

4.2Tools

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.

1.2Special 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.

1.2.1Safety when connecting

Work only on those connections for which you are qualified.

1.2.2Safety 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.

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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.

1.2.3Safety when cleaning

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Before cleaning, protect the floor against 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 dosing vessel for compressor washing.

1.2.4Safety 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.

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When disassembling, secure the rotolagainst turning.

Ensure that absorbent material is available

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to soak up any spilled fluids.

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.

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1.3Hazards 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!

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 a n d the turbocharger clean

Ensure t h e availability of oil - absorbing materials.

Eliminate leaks

1.3.2Operation 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

1.3.3Noise

Physical injury

A warning!

Loss of hearing, deafness impairments of health such as loss of balance or of consciousness, cardiac and circulatory disturbances.

Causes

Machine noise level in excess of

S O ~ B ( A )

Protective measures

Wear ear protection

2.Construction and function

2.1Construction 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-floatingtype is employed.

A conventional floating bearing rotates, but

semi-float bearing (7001) don't rotate.