Maintenance of RH..

3 Turbocharger

6N18, 6/8N21,DY25 & 26,6N25 & 26

Engine Model
Model

02-2-G-2-006-L
2002.02.22
Date:22.Feb.2002

Use

Industrial, Marine Main & Aux.

Engine Nos.

RH3 VTR

RH133 RH203 5 2500

RH133

The RH..3 Turbocharger is the newly developed turbocharger, to be replaced with the conventional
VTR turbocharger, which features high turbocharging ratio, high performance and easy maintenance.
The new turbocharger series comprises models ranging from RH133 to RH203. The deliveries of the
turbocharger series to now count 2,500 units in past 5 years. Over the period, the RH133
turbochargers have undergone several improvements to the reliabilty in the past. However, there
have been several cases where improper maintenance of the turbocharger has caused turbocharger
trouble. In order to avoid such failures, we have summarized the important maintenance points for
the turbocharger as follows. Refer to these points for your maintenance.

For details please refer to the attached materials

RH143/RH163
RH183/RH203

Check of bearing clearance

Every 2400 hrs.
Same as the intervals for disassembly,
cleaning and servicing

Disassembly,Cleaning & Servicing

Hrs

Blower Cleaning
Weekly
LO
AUT
Operation of LO Priming Pump
Operate in AUT mode. (Be sure to operate the priming pump
while the engine is being stopped.)
:

:

Thrust clearance Thrust clearance Thrust clearance

0.060.12mm
0.080.15mm
Replace the bearing according to the 0.060.12mm
rotor shaft clearance measurement

Radial clearance Radial clearance Radial clearance

Max0.8mm
Max0.80mm
Max0.67mm

Replacement of Seal Ring

Replace whenever turbocharger was disassembled.
RH133,RH143/163,183/203
Attached materialsRH133,RH143/163,183/203 Turbocharger Operation Manual Revisions

Approved

LARGE POWER PRODUCTS OPERATIONS DIV.

QUALITY ASSURANCE DEPT.

FAX No.06-6488-4003

..+81-6-6488-4003

Checked

Drawing

P.1/7

A Supplement to

manual of RH133

Photo 1

Compressor Impeller
Turbine shaft

1. The points of Inspection

RH133

1.1

1.1 Every 400 hours: Check all fixing bolts

This check is to prevent a leakage of exhaust

gas and lubrication oil due to looseness of bolt
and nut.

Compressor housing
1.2

rotation of rotor

Photo 2

(Photo 1)

(Photo 1)

1.4

Check if the rotor rotates smoothly by hand. If the

rotor rotates heavily or touching noise occurs, the
turbocharger must be dismantled for inspection.
Refer to the Instructions and Chap.1.4

Do not push the blades of

compressor impeller

1.3 Every 2400 hours: Check the

1.3.1 How 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.

1200 :

Axial clearance 1

Caution

clearance of rotor

Note

1.2 Every 1200 hours: Check the

400 :

Photo 3

Axial clearance 2

1.3 2400 :

1.3.1

Photo 2

Photo 3

RH133AP-1.R0

P.2/7

Radial 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.

Photo 4

Radial clearance 1

Photo 4

Photo 5

Note

Repeat

the measurement at least 3 times, and

check if the average recording is within
permissible range in below Table 1.3.2. In case
of overhaul or inspection, refer to the Instructions
manual and Chap.1.4

Photo 5

Radial clearance 2

1.3.2

1.4

Caution

Cover

Lub. oil inlet and outlet with rag to avoid

dust invasion.

LO

impeller is made of AL-alloy. Be

careful not to make the impeller blades bent or
damaged.

Compressor

1.3.2 Permissible range of clearance (mm)

Turbocharger
RH133

1.3.2 mm

Axial

Radial
(When delivered)

0.060.12

0.67
0.370.57

RH133

0.060.12

0.67
0.370.57
RH133AP-1.R0

P.3/7

1.4 Every 4800 hours: Overhaul and

inspection

1.4 4800 :
Fig. 1

Turbine housing
1.4.1

1.4.1 Instructive points of overhaul

It

is recommendable to have overhaul cleaning

and inspection at every about 4800 hours use. In
case heavy contamination is found, the interval of
overhaul should be adjusted as occasion
demands.

Shroud
part

Be

careful the carbon covered over the shroud

part of turbine housing is quite hard to remove it
and looks like metallic surface.

Check

4800

Gas passage

Pos.1 Coated part

if there is groove due to erosion on the

surface of gas passage.

RH133

Clearance 1+32+4
Design value in mm
0.75 2 = 1.50

Clearance
Measuring
Position

Clearance gauge

Please

R1+R3R2+R4
mm

RH133

0.75 2 = 1.50

GasOutlet

1
4

Radial tip clearance at gas outlet part

Type

1
4

2
3

check and clean if carbon and sludge of

lubricating oil accumulate at back wall of turbine
impeller and groove of seal ring.
(Refer to Chap.1.4.4)

Seal ring and

groove
Turbine wheel

(1.4.4 )
RH133AP-1.R0

P.4/7

Caution

Recommended

replacement interval of floating

and thrust bearing is 2 years.

In

case of turbine wheel cleaning by soaking in

hot water or carbon removal solvent, rust
preventive oil must be applied to the turbine shaft
from groove for seal ring to the end of
compressor-wheel side before soaking of it. If
protection is not enough, corrosion can be
occurred. Refer to Fig. 2

Soak only turbine

wheel part up to
rear wall in hot
water or carbon
removal solvents.

This part must

be covered by
rust preventive
oil.

Seal ring must be replaced at every overhaul and

remove the carbon deposits from sealing groove,
if accumulated. As for the wear of sealing groove
of turbine shaft, refer to Fig. 3.

Fig. 3

Fig. 2

Worn area

Usable

Unusable

Fig.2

Fig.3
For referenceStandard Dimension

2.36 mm

Turbine
wheel side

Turbine
wheel side

RH133AP-1.R0

P.5/7

1.4.2 Cleaning of Turbine side parts

Carbons at shroud part of turbine housing and
turbine wheel normally include very hard layer of
Calcium and Vanadium. Therefore clean them by
hard wire brush or scraper. (Remove the dropped
deposits in turbine housing surely after cleaning.)

1.4.3 Cleaning procedure

Turbine wheel

Photo 6
1.4.2

Photo 7

Air-wire brush

Sample after cleaningPhoto 6

1) Remove the carbon carefully by wire brush or
scraper.
2) If it's hard to remove the carbon, soak only
turbine wheel in hot water or carbon removal
solvents according to Chap. 1.4 Fig. 2.

Turbine housing

Shroud part
1) Remove the carbon carefully by wire brush or
scraper.
2) If it's hard to remove the carbon, penetrate the
cleaning solvents in way of covering by wet rag
that is soaked with solvents.
3) Photo 7, 8 show a sample of utilizing cleaning
tools. This pneumatic tool that has bundled
about 30 wires (2mm/pc) works effectively to
remove carbon deposits on gas passage. Use
it not to damage material of turbine housing
itself. Also do not use it for cleaning of turbine
wheel in order to prevent the damage for
turbine wheel.

1.4.3

Photo 6
1)

2) 1.4 Fig.

Photo 8
Shroud

Coating area

Photo 9
Air wire brush

1)

2)

3) Photo 78
2mm1 30
T/H

RH133AP-1.R0

P.6/7

The

Caution

degree of contamination on turbine wheel

and its surrounding area differs from the
individual operating condition. Even after the
certain running hours shorter than the
recommendable overhaul interval, thick carbon
may accumulate on turbine wheel and the area
surrounding it. Excessive unbalance causes
touching of turbine impeller and compressor
wheel at shroud part, which may lead to
damage of bearing part. Therefore special care
should be taken so as to overhaul and clean
earlier for prevention if engine is running with
heavy fuel oil.

Photo 10

Bearing
housing

Photo 11

Remove

the carbon deposits on turbine wheel

evenly as much as possible. Uneven cleaning
may cause the unbalance of rotor.

Confirm

that the rotor can turn smoothly by

hand after cleaning.

Sealing section in
bearing housing

In

case of the coated turbine housing, do not

damage or tip the coated parts when cleaning
gas passage.Fig 1 Pos.1

1.4.4 Accumulation of carbon deposits

Oil leakage or bearing damage can be occurred
by coking of lubrication oil around the sealing
section, because of heat soaking from turbine
impeller after engine stopped.
Photo 10 shows slightly coked deposits in LO
space around seal ring at turbine side
Photo 11and 12: After cleaning. If accumulated
carbon deposits are observed around it, remove
deposits and do not damage the sealing surface.

Photo 12

Seal ring and

groove

Fig. Pos
1.4.4

Photo 10
LO

RH133AP-1.R0

P.7/7

The seal ring must be renewed at every overhaul.

Engine stop without cooling

down

Seal ring part

In order to mitigate the coking phenomenon, Temp. ()
idling operation before engine stop is

recommended for more than 15 minutes.

()
Ref. Fig 4
In case it is impossible to do idling, start a priming
pump as soon as engine stopped and supply
Lub. oil for more than 15 minutes.
(Remark 1)
Remark 1
Such priming pump may automatically or always
be operated during standstill according to the
engine specification. For the detail, consult with
engine builder

Coking range

Coking range
Coking range

Photo 1112

15
Fig.

15
()
1

Caution
In case the engine is forced to stop emergency,
the following measures must be done.

Cooling-down by Lub. oil-priming pump should

Time

Before re-starting of the engine, check the rotor

condition according to Chap. 1.2. (Inspection at
every 1200hours) In case abnormal condition
of rotor is observed, carry out the cleaning and
overhaul inspection of the turbocharger.

LO stop

be done immediately.

Fig.4

Engine stop with cooling

down

(1.2 1200 )

RH133AP-1.R0

P.1/7

A Supplement to

manual of RH143/163,183/203

Photo 1

Compressor Impeller
Turbine shaft

1. The points of Inspection

RH143/163183/203

1.1

1.1 Every 400 hours: Check all fixing bolts

This check is to prevent a leakage of exhaust

gas and lubrication oil due to looseness of bolt
and nut.

Compressor housing
1.2

rotation of rotor
Caution

Photo 2

(Photo 1)

1.3.3

Check if the rotor rotates smoothly by hand. If the

rotor rotates heavily or touching noise occurs, the
turbocharger must be dismantled for inspection.
Refer to the Instructions and Chap.1.3.3

Do not push the blades of

compressor impeller

1.3 4800

1.3 Every 4800 hours: Check the

1.3.1 How 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.

1200 :

Axial clearance 1

(Photo 1)

clearance of rotor

Note

1.2 Every 1200 hours: Check the

400 :

Photo 3

Axial clearance 2

1.3.1

Photo 2

Photo 3

RH143-203AP-1.R0

P.2/7

Radial 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.

Photo 4

Radial clearance 1

Photo 4

Photo 5

Note

Repeat

the measurement at least 3 times, and

check if the average recording is within
permissible range in below Table 1.3.2. In case
of overhaul or inspection, refer to the Instructions
manual and Chap. 1.3.3.

Photo 5

Radial clearance 2

1.3.2

1.3.3

Caution

Cover

Lub. oil inlet and outlet with rag to avoid

dust invasion.

Compressor

impeller is made of AL-alloy. Be

careful not to make the impeller blades bent or
damaged.

1.3.2 Permissible range of clearance (mm)

Turbocharger
RH143
163
RH183
203

Axial
0.060.12
0.080.15

Radial
(When delivered)
0.80
0.450.60
0.80
0.450.60

LO

1.3.2 mm

RH143
163
RH183
203

0.060.12
0.080.15

0.80
0.450.60
0.80
0.450.60
RH143-203AP-1.R0

P.3/7

1.3.3 Overhaul and inspection

Instructive points of overhaul

It

Fig. 1

is recommendable to have overhaul cleaning

and inspection at every about 4800 hours use. In
case heavy contamination is found, the interval of
overhaul should be adjusted as occasion
demands.

Be

if there is groove due to erosion on the

surface of gas passage.

Gas passage

Type
RH143163

0.70 2 = 1.40

RH183203

0.90 2 = 1.80

Clearance
Measuring
Position
4

GasOutlet

1+32+4
mm

RH143163

0.70 2 = 1.40

RH183203

0.90 2 = 1.80

1
4

Clearance gauge

check and clean if carbon and sludge of

lubricating oil accumulate at back wall of turbine
impeller and groove of seal ring.
(Refer to Chap.3)

2
3

Please

Pos.1 Coated part

Radial tip clearance at gas outlet part

Clearance 1+32+4
Design value in mm

4800

Shroud
part

careful the carbon covered over the shroud

part of turbine housing is quite hard to remove it
and looks like metallic surface.

Check

Turbine housing

1.3.3

Seal ring and

groove
Turbine wheel

(3 )
RH143-203AP-1.R0

P.4/7

Caution

Recommended

replacement interval of floating

and thrust bearing is 2 years.

In

case of turbine wheel cleaning by soaking in

hot water or carbon removal solvent, rust
preventive oil must be applied to the turbine shaft
from groove for seal ring to the end of
compressor-wheel side before soaking of it. If
protection is not enough, corrosion can be
occurred. Refer to Fig. 2

Soak only turbine

wheel part up to
rear wall in hot
water or carbon
removal solvents.

This part must

be covered by
rust preventive
oil.

Seal ring must be replaced at every overhaul and

Fig.2

remove the carbon deposits from sealing groove,

if accumulated. As for the wear of sealing groove
of turbine shaft, refer to Fig. 3.

Fig. 3

Fig. 2

Worn area

Usable

Unusable

Fig.3

For referenceStandard Dimension

RH143/163 1.87 mm
RH183/203 3.37 mm

Turbine
wheel side

Turbine
wheel side

RH143-203AP-1.R0

P.5/7

2. Cleaning of Turbine side parts

Carbons at shroud part of turbine housing and
turbine wheel normally include very hard layer of
Calcium and Vanadium. Therefore clean them by
hard wire brush or scraper. (Remove the dropped
deposits in turbine housing surely after cleaning.)

2.1 Cleaning procedure

Turbine wheel

Photo 6
2.

Photo 7

Air-wire brush

Sample after cleaningPhoto 6

1) Remove the carbon carefully by wire brush or
scraper.
2) If it's hard to remove the carbon, soak only
turbine wheel in hot water or carbon removal
solvents according to Chap. 1.4 Fig. 2.

Turbine housing

Shroud part
1) Remove the carbon carefully by wire brush or
scraper.
2) If it's hard to remove the carbon, penetrate the
cleaning solvents in way of covering by wet rag
that is soaked with solvents.
3) Photo 7, 8 show a sample of utilizing cleaning
tools. This pneumatic tool that has bundled
about 30 wires (2mm/pc) works effectively to
remove carbon deposits on gas passage. Use
it not to damage material of turbine housing
itself. Also do not use it for cleaning of turbine
wheel in order to prevent the damage for
turbine wheel.

2.1

Photo 6
1)

2) 1.4 FIG.

Photo 8
Shroud

Coating area

Photo 9
Air wi
wire
re brush

1)

2)

3) Photo 78
2mm1 30
T/H

RH143-203AP-1.R0

P.6/7

The

Caution

degree of contamination on turbine wheel

and its surrounding area differs from the
individual operating condition. Even after the
certain running hours shorter than the
recommendable overhaul interval, thick carbon
may accumulate on turbine wheel and the area
surrounding it. Excessive unbalance causes
touching of turbine impeller and compressor
wheel at shroud part, which may lead to
damage of bearing part. Therefore special care
should be taken so as to overhaul and clean
earlier for prevention if engine is running with
heavy fuel oil.

Photo 10

Bearing
housing

Photo 11

Remove

the carbon deposits on turbine wheel

evenly as much as possible. Uneven cleaning
may cause the unbalance of rotor.

Confirm

that the rotor can turn smoothly by

hand after cleaning.

In

case of the coated turbine housing, do not

damage or tip the coated parts when cleaning
gas passage.Fig 1 Pos.1

3. Accumulation of carbon deposits

Oil leakage or bearing damage can be occurred
by coking of lubrication oil around the sealing
section, because of heat soaking from turbine
impeller after engine stopped.
Photo 10 shows slightly coked deposits in LO
space around seal ring at turbine side
Photo 11and 12: After cleaning. If accumulated
carbon deposits are observed around it, remove
deposits and do not damage the sealing surface.
The seal ring must be renewed at every overhaul.

Sealing section in
bearing housing

Photo 12

Seal ring and

groove

Fig. Pos
3.

Photo 10
LO

RH143-203AP-1.R0

P.7/7

Engine stop without cooling

down

In order to mitigate the coking phenomenon,

idling operation before engine stop is
recommended for more than 15 minutes.
Ref. Fig 4

Seal ring part

Temp. ()

()

In case it is impossible to do idling, start a priming

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

Coking range

Remark 1
Such priming pump may automatically or always
be operated during standstill according to the
engine specification. For the detail, consult with
engine builder

Photo 1112

15
Fig.4

15
()
1

Time

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 Chap. 1.2. (Inspection at
every 1200hours) In case abnormal condition of
rotor is observed, carry out the cleaning and
overhaul inspection of the turbocharger.

LO stop

Fig.4

Engine stop with cooling

down

(1.2 1200 )

RH143-203AP-1.R0