IHI RH183, RH183L User Manual

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EXHAUST GAS TURBOCHARGER

R%S

TYPE

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Bearing housing with foot

RH183/183L/203

(Version

:

Y

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71Jj3'

n92'

8'

>Y)

(Semi-f loat bearing)

aaRMY14

Instruct ions

for operation and maintenance

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Ishikawajima-Harima Heavy Industries

TOKYO

JAPAN

Co.,

RH183FSYA-

Ltd.

R3

TSU

(fi~*Y-cx%)

9-$925-AX

TEL [phone]

FAX [phone]

TEL [phone]
FAX [phone]

TEL [phone]
FAX [phone]

J-f-f

03-5950-0491

5-Y

FR3ea

(24hrs)

TSU

Turbo

Systems United

Tokyo

East Japan Service Dept.

Arca Central Building 18F 2-1, Kinshi

1-

chome, Sumida-ku, Tokyo 130-0013,

JAPAN

TEL

FAX [phone]

[phone]-5986
[phone] (24hrs)

East Japan Service Station

22- 1, Honjo

Tokyo 130-0004, JAPAN

TEL
FAX [phone]

1-

chome, Sumida-ku,

[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

TEL

FAX [phone]

Service Dept.)

[phone]

Co.,

Ltd.

(%EI*Y--Exx7--93

TEL [phone]
FAX [phone]

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799-1506

3-9-36-303

TEL [phone]
FAX [phone]

TEL [phone]
FAX [phone]

%%?E+%vdmSfF$;f

(West Japan Service Station)

TEL
FAX [phone]

[phone]

Imabari Office

3-9-36-303, Higashimura, Imabari-shi,
Ehime 799- 1506, JAPAN

TEL
FAX [phone]

[phone]

Kyushu Service Station

1418, Aza-Daima, Ueki, Suemachi,
Kasuya-gun,
JAPAN

TEL
FAX [phone]

Fukuoka

[phone]

811-2112,

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FOREWORD

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To make full utilization of the
turbocharger (hereinafter briefly called
"turbocharger"), it is important to comply with
the procedures for operation and maintenance

as well as instructions contained in this
instruction manual.
Operate the turbocharger after reading through
this instruction manual.

IHI

Exhaust-Gas

CAUTION

1.

Order and inquiry

(1)When ordering the parts, clearly indicate the

following symbols in your order sheet.

Type

RH

...

Serial- No,
Specification plate of turbocharger

Part number
and designation
Quantity

(2)Address your order and inquiry to our

agencies and service offices or engine
builder's service stations.

2.Exemptions of liability
In respect of accidents during the guarantee
period that are recognized as being clearly
attributable to
IHI will make repairs free of charge, but
will assume no responsibility even during the
guarantee period for the following accidents.

As stamped on the rating

(Refer to Fig.

As per

I

parts list(sect.2-2)

IHI's design or manufacture,

l,sect.2-2)

Fig.2bect.2-3) and

IHI

(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 in 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
temperature and high-speed condition.

(2)Dismantle or remove the turbocharger after

getting cold.

turbocharger is in a high

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

it

marked with this symbol are not,
observed.

Warning signs must be strictly observed.

only partly,

/i\

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

Work can

simply when work and operation instructions
marked with this symbol are observed.

Notes help to simplify your work.

Caution!

Note

be

carried out more efficiently and

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

turbocharger.

Work on a turbocharger only in
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.

or operating the

a

stable

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 as 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

1.2.2

Safety when connecting

Work only on those connections for which

you are qualified.

Safety when commissioning and

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.

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Refrain from any

Impair safety at the turbocharger.

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which

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Inspect the turbocharger approx. every

hours or at least once a day for visible

external damage and defects.

Report immediately any damage or changes
in operation performance to the person
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.

12

1

1.2.3

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Before cleaning, protect the floor against
unintended leaks of oil and operating
materials.

Wear protective clothing (oil
resistant gloves, protective suit, eye
protection, knee protection, foot

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.

Safety when cleaning

-

and petrol

protection).

-

1.2.4

Safety 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.

When disassembling, secure the

against turning.

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Ensure that absorbent material is available
to soak up any spilled fluids.

Ensure that operation and process
materials are drained, collected and
disposed of in a safe and environmentally
compatible manner.

Ensure that the prescribed, adjustment,
maintenance and inspection work is carried
out at 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.

rotol-

1.2.5

Safety when shutting down

Secure the rotor against turning.

Clean the turbocharger before mothballing.

Wear protective clothing during
mothballing the turbocharger.

and

Keep the work area clean
and operating materials.

Remove any obstacles laying
floor.

free

al-ound on the

of oil

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 maintenance and
inspection work

1.3.1 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

and gases under pressure or in a

vacuum

(e.g. springs), liquids

slippery, oily work area, obstacles on

the floor

Protection measures

Wear Leather protective gloves

Wear close-fitting protective clothing

Tie up long hair

hair protection

Wear face and eye protection

Wear protective shoes

Keep floor, equipment and the
turbocharger clean

Ensure the availability of oil

absorbing materials.

Eliminate leaks

1.3.2

Operation and process materials

This includes all substances such as oil,
grease, coolant, detergents and solvents,
acids and other hazardous substances.

Physical injury and damage to property

and bearings, wear

-

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
operation and process materials and
penetration into soil and water.

Causes

Inhalation of toxic gases, smoke and
vapors

Skin contact with aggressive fluids

Clothing wet or soaked with hazardous

substance

to

leakage of

Spilling and tipping
with operation materials

ovc~

of vessels

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 as prescribed, and
disposed of as special waste in an
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 an 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 as loss of balance or of
consciousness, cardiac and circulatory
disturbances.

Causes

Machine noise

90dB(A)

Protective measures

Wear ear protection

level

in

excess

of

1.3.3

Noise

A

Physical

injury

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

SO~B(A)

Protective measures

Wear ear protection

of

2.

Construction and function

2.1 Construction of the turbocharger
RH1831203

The
type turbocharger consists essentially of a
mixed flow turbine and a radial flow
compressor assembled as a single unit.

(1) Turbine

The exhaust gas from the diesel engine flows
through the turbine housing
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
provided so that gas may not adversely affect
the bearings.

(2)

Compressor
The compressor wheel
turbine shaft
torque, induces air through the silencer

(10001), and delivers it to the cylinders after

compression.

Seal

provided so that air and oil may not leak.

1009) and heat shield (5005) are

(2001) fitted to the

(1001) receives the rotating

plate(6001) and seal ring(1010) is

(4001) to the

(3)

Bearing

A.

Thrust bearing(7002)
Since thrust force is constantly applied to
the turbine shaft
(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

(1001), the thrust bearing

(7001) don't rotate.