@onware ATTACHED SERVICE MANUAL for the ENGINE AIR STARTERS, YANMAR SERVICE NETWORKSINSPECTION INSTRUCTIONS FOR MODEL 45MA AIR STARTER CONTROL MODULE 1. Before Inspection Bo sure to release the air pressure of the system before setting: about the inspection. When the starting power voltage of the air starter 45MA is 24VDC, refer to Fig.Lbelow. When the voltage is 100VDC refer to Fig2 (Control Modi for 24VDC: Pert Number 2-24775-005 / Yanmar Part No. 46679-77191 (Contral Modul for 100VDC: Part Number 2-24776-005'/ Yanmar Past No.46679-77211 2. Inspection. 2-1, Trouble: The air starter doos not start even with the application of the ‘normal sir pressure. ‘Measure It is possible that no power is supplied tothe control module [Remove the screws at the input and output connectors (see Fig.2 below) and pull them out from the control module body. Check that the power voltage is supplied to the input side connector lead wire. 2-2. Trouble! Solenoid valve doas not open even when the power is supplied to ‘the control module Measure: © Check the control module body: Impress the power voltage to tho plus (+) and minus () poles of the input terminal and measure the voltage of the output terminal. The function is normal when the power voltage as impressed appears. © Chock the solenoid valve: Supply 0.2MPa (2kg/em) air pressure to the NC (normal closed) piping of the solensid valve removed from the control module. Impress DC12V between the terminals (no polarity) of the solenoid valve, open it and check for the function. If the solenoid valve is normal, replace the control module @ Whea the function ofthe solenoid valve isnot normal: YANMAR CO.,LTD. Pagearra[Remove the elbow, loosen two nuts ofthe solenoid valve, turn ‘the eol housing (with sealed in black resin) counterclockwise for loosening and remove it from the (aluminum) valve body. Loosen the three screws and check thatthe valve pot is not clogged with impurities. If tis clogged, clean the port and check the function of the valve again according tothe instruction af @ above ‘Fig Module for 24DVC Power Fig 2 Module for 100DVC Power 2006. 2.15 Pape arTa‘MODEL 45MA AIR MOTOR SERVICE INSTRUCTIONS FOR YANMAR DIESEL ENGINE MODELS, 6N18(L), 6 & 8N21(A) ENGINES (© Cautions for Disassembly © The dimensions of this air motor are represented in the inch unit. Allbolts come with six oles. Apply LOCKTIGHT (screw bonding agent) to the threads, @ Lae ol is sealed in the sealing type bearing and the starter drive. Do not wach these items. @ Feed 80g specialized grease inside the reduction gear for ubrication. For (O-rings and other items, use AEROSHELL #8 or equivalent gease, © Me air motor can be disassembled largely into the drive housing (61), gear bor housing (66), ring gear (49), contained ring (18) and inlet housing (6) ‘Mark alignment marks on each part before disassembly. YANMAR CO.LTD. 002738 PagearrsTDI TURBOSTART TVV/O™ from TECH DEVELOPMENT INC. SECTION7.O PARTS LIST vy zy 2 ee co 5 3 ee eo 2 ee 2S - noe) Soe 5 = = a » te) tee - Ce te eee ee oofeecmee teers | Perr eeeeee te a Bape | Fe eeteve ear tee EF | Seckoi Head Cap Sew (5) Het 6 ee ease pial ere ve] See 7 [merece Longmen] [at Sees Eres Se ed ie nea le re Tinseat | A See = ome oan fee (Te [acme ee] of esieas oe eee == ate — ee fe | it ee SS ee eee a ee | = a Es ee Se SF eee Se ae ) gpa a a | Baad Sa WET ep Pe ee = = 5 a 2 a = eee a Sa —- team See See ee iste Sa ssiao8, Sees (eee ea [eee Lenses aes a + tS t-Sesignsies pars included in it a AEFER TO PAGE 17 FOR LISTING OF NOM Page ATES IMLUSTRATED PARTS,Publication 45-723, Edition Dated: November, 1991 SERVICE MANUAL for the MODEL 45M ENGINE AIR STARTERS TDI TURBOSTART TWO™ Engine Air Starters From TECH DEVELOPMENT INC.TDI TURBOSTART TWo™ from TECH DEVELOPMENT INC. SERVICE MANUAL for MODEL 45M AIR STARTERS COMPRESSED AIR USE ONLY ‘CONTACT FACTORY FOR OTHER APPLICATIONS. ‘TABLE OF CONTENTS ‘SECTION ‘SUBJECT PAGE 10 20 20 40 50 60 29. rrooueTion DESCRIPTION OF BASIC GROUPS DISASSEMBLY (CLEANING AND INSPECTION ‘ASSEMBLY ‘TROUBLE SHOOTING GUIDE PARTS LIST LIST OF ILLUSTRATIONS FIGURE TLE PAGE 1 net Housing - Nozzle Vave Seat iad Turine Housing 3 ‘lage One Gear Carer and (Geatbor = Dive Housing ‘Tuine Rotor Removal Insaling Turbine Housing Lip Seal Inang Turbine Saft Ball Bearng Irsang Turbine Shaft Insating Bearing Hub Lip Seal del 45M Pars Key Numbers 2 8 LIST OF TABLES TABLE THLE, PAGE 1 Clearing Materials and ‘Compounds Parts Inspection Paris Dnensons ‘Torgve Values SECTION 1.0 INTRODUCTION 14 GENERAL INFORMATION “This manual povides complete instr for senic- Ing, pais replacement and e-assemby of the TO! ‘Tutostan Two™ Mode 45M a tater. Whore are qiestons not answered by hs manual please coract Your TD Tubosta ™ dstbutor or ales or asi {ance lusrations and exploded views wah pars in- ‘xing are provid oad dsascomby ana e-as- sembly. ‘The Model ASM is a turbine diven ai starter wih apre- ngage slater ive. It beet sued fr desal engines tpi 1220 CID 201). The Model 45M cesignea for ‘fetalaton on engnes whieh use an SAE 1,2, 0r3 ‘mounting pac. “The Model 45M fs sulle 0 operate win a wide range oll a pressures, ambient lemperaturs, and corso! ‘oages. Tank preseute of 120 PSIG wil generally ro- ‘ide elabe staring Proughout the Model 45M epera- tng range. ‘The Model 45M i designed for operation wth com- Drotsed ai. Small anaurts of foreign mater Baud in {he a steam wil normaly rot adversaly affect tho Model 45M. As wih at other TDI Tubostar™ models, ro brcaon i required inthe supply a “The Model 45M comes complete wit ait ar sole roid vane installed. The excuse TOI Tubostat “Two™ secre contol module reads output shat peed and shuts of aio the Model 45M etn case ot ‘an overspeed conditon, This provers excessive Cranking speeds, whic coulé damage he state or ‘waste comprested a ‘You neato review the resto his manual betore a smoting o provide service on the Ot Turbos fwo™ Meal 45M,1.2 WARNINGS, CAUTIONS, & NOTES ‘Throughout this manual, certain ypes of iformaton wiloePighighted for your attri: WARNING -used whore iy to personnel or ‘damage fo the equipment is hey CAUTION used where thar is the possibilty ‘of damage tothe ecupment [NOTE--used o point out special terest intr ‘maton, NOTE "THE MODEL 454 15 TO BE SERVICED ONLY BY [AUTHORIZED AND PROPERLY TRANED TO! ) | TuRBOSTART™ DISTRIBUTORS, DEALERS, AND REPAIR STATIONS. DO NOT OPERATE ‘THIS STARTER WITH COMPRESSED AIR UN LESS IT IS PROPERLY ATTACHED TO AN EN- GGINE AND WILL ENGAGE THE FLYWHEEL “The TO! Tubostan Two Medel 4SM provides ditint ‘vantages of size and eficieney as compared 10 ‘hectic moor, vane-ype oF other oie ype a stat (15. Bis portant forte operator to propery instal {he Model 46M to receive fl beef these advan tages. Repartectricans or serdceomanizaons TDI TURBOSTART TWO™ From TECH DEVELOPMENT wihout turbine starter experiance shoud not attempt {orepat tis machine un they receive factor ap proved aang om TD, o is ropreertaves Prop {operation ad repair ot your TD TuostatTwo™ ‘wal assure continues relable and super per tance for many years WARNING “The TOI Turbos TwoO™ Model 4M must be F- stalled and operated in acordance with he ine {ons gen nthe Inaaltion and Operating manda. False to propery isa the stator o aro 1 op fate according to these nsructions may res a damage otha starter or engine personal ny. SECTION 2.0 DESCRIPTION OF BASIC GROUPS 24 GENERAL “The Model ASM can deserve be grouped into four basic sogments: (1) ret Housing - Nozze / Vale Seat; (2 Tubine Housing: (3) Stage One Gear Car fer and (4) Gonrbox-OrveHoveing. Secon 3.0 Ds- ‘zeny and Secton 6. Asser wl general lew te above mertioned groups fr instuction. rosTDI TURBOSTART TWO™ ‘from TECH DEVELOPMENT INC. 22 INLET HOUSING - NOZZLE / VALVE ‘SEAT efecto Figure 1, The Inlet Housing Nozzle - Valve Seal area genera iets tems (1) tough (25). You sted noe hat some toms, suchas contol Kes ‘acsrsed where they are best, 2.3 TURBINE HOUSING elec 'o Figure 1. The Turbine Housing incudes ems (26) trough 38. 2.4 STAGE ONE GEAR CARRIER Fler o Figure 2. The Stage One Gear Case area Iretdes tee (9) tough (47), ls the rng gear aces (48, 48,5) 2.5 GEARBOX- DRIVE HOUSING eter to Figure 2. The Gearbox! Drive Housing area Irchdes Res (1) Uvough (83). You shoud note that some toms, sch as contol nes, ae adaressed whore they ate bes omaved are assembled. ‘Figure 2. Stage One Gear Carer and Gearbox - Drive Housing SECTION 3.0 DISASSEMBLY 3.4 GENERAL Mark each socton othe stator for eference during assemby. ve house (81), coarbax housing (6). fing goa (48), cortament ain (18), and net Rousing (5) Note the location ot the long male ebow (19) 9 ‘he rozze valve seat (16). Note ta the corr ine faccess hol inthe cortaitment tng (18) andthe por inthe nozzle valve cat (16) must ine up when as sembled. Pome Marke turbine tor (28) ad note ts direction o 10> talon, Have a complete set of Ovings, seals, crews, and risoolaneous Rardware avaiable fo asserbiy. od (145 starter overhaul kl, TOI PIN 45-007 cota all necessary prs. CAUTION ‘Do not wash bearings (93,45, 52, 62 or the stan Chive (78) meaning sovents3.2 GEARBOX.- DRIVE HOUSING 324 Generat Remove the two corto! ine hoses (2,88) and four bows (18,21). Disconnect he solenoid valve (6) rom the controlar ‘module (60). Remove the vee screws (62) and be solenoid valve (63). Ferove the seven ecrows (61) and he convoer module (0) 222 Dive Housing WARNING “Te ive housing - gearbox housing is sping oad ‘Exercise caution when separating the orve housing (81 fom the gearbox housing (6). Remove the twelve screws (83) and separate te ve housing (81 trom the gearbox housing (6). ‘Check the condton ofthe roller bearing (2), Press ‘out damaged or suspect. Reravo the compression spring (78) and he starter ‘iv (78) om the gearbox housing (66). The Wo spt ings (7 wil come ut wih ho stare eve (78), WARNING old rag over the output shaft (55) and gearbox housing (65) to stop the pre-engage piston (75) when applying ow pressure ate remove om the gearbox housing (66). ‘Apply ow pressure ito the solo port on the gear- box housing (68) o force the pre-engage Psion (75) ‘dof he gaarbox housing (6). tere the WARN- ING above. 3.23 Gearbox Housing ‘Remove the four screws (7) and separate the goar- box housing (68, rg ger (49), stage one gear ear- (47, tune hosing (32) and let housing = nozzle aie seat, 1) Fem the etainesig (73) and wo thst washers {72} rom the output hak 5). io ee TDI TURBOSTART TWo™ ‘rom TECH DEVELOPMENT Remove the gear cartier / output shat (5) rom the ‘gearbox housing (6) ‘Remove the four screws (64) andthe bearing ib ©. Press out hop seal (71). (Check the contin of he bronze bearing (58). Press ‘uti damaged or suspect. Remove te tree screws (57) ane the magnet cap a. Press out he tre stage two planet gear shalt (54) {and remove the gears (58) and gear spacers (1). ‘Check he condton ofthe need beatings (52). Press out I damaged or suspect. 3.3 STAGE ONE GEAR CARRIER Remove the two shins (49) rom the sun gear. ‘Remove the thee screws (88) andthe stage one plan- 1 gear shaf retention plate (40). Press out the tree ‘sats (42) and remove the gears (46) and grease, eps (64) ‘Chock the condition ofthe needle bearings (45). Press out damaged or suspect 3.4 TURBINE HOUSING Remove the si screws (2), thee retainer pats (24), ‘2nd mur retaner (25) fom the conta ing (8). Remove the thre mir elements (22) and de car, Remove the turbine housing assent (82) tom the containment ng (12). ‘Remove te ftor eortion srw (26) and rotor wash- 6 @7) trom the turbine shat (38), NOTE is suggested that you old the sun gear end ofthe turbine shaft (9) ina sot jawed alurinum) vise le removing the tr rleiion sew (24),TDI TURBOSTART TWO™ From TECH DEVELOPMENT INC. any eee) Ld be onset 9 Be igure 3. Turbine Rotor Removal Remove the turbine rotor (28) rom the turbine shat RetertoFigue 3. Hold onto the per eolwih an ‘open end wrench NOTE Tnsalthe three puller screws hand ight the We bin oor (28). Belov nstaling the pul oo, ‘cack to make sue thal the face of he see ‘smaler than he ameter ofthe turin shat (38) ‘Remove he 1/8" kay (29) tom the turbine shat (2). ress the bin shaft (28) trom the wine housing (32), Tae bearing spacer (96) shoul come ou, ao. Remove the bearing spacer (96) rom the turbine shat oo. CAUTION ‘You hat pressing tool mus be smaller ameter than he trbne shal (172). Press he bal bearing (39) rom the tune shaf (38), Pape Remove the compression spring (95) om the turbine housing (2) Remove the Ong (37) from the tube housing 22). Remove he retainer ng (34) rom the turbine housing 3a amore he bl ben (3 tom heating fe NOTE ‘You shouldbe able o push the bal bearing (33) out ‘by pressing onthe seal spacer (20) wih younger. ‘The seal spacer (20) wil come ou, als. ‘Support the urine housing (82) and pres but the fp seal (31). Use TO! pressing tool PN 45-25302. 35 INLET HOUSING - NOZZLE / VALVE SEAT the threaded inet (2A) i used, remove the four screws (1). Remove the threaded inet (24) rom the Inet housing (5), Remove the four screws (7) and soparate the inlet hosing (5) rom the containment fg (1). Remove the five screws (6) and separate the nozzle vale seat (18) from te inlet housing WARNING ‘he spool valve - nozzles spring aded. Exercise auton when separating heel housing (5) ror the nozzo /vave eet (8) ‘Remove the spring (10) rom te spool valve (12). Re- ‘move the O-ng cap (11) tom the spool valve (12). Remove the shock dampener (9) rom he spool vale (a. Remove and discard the O-ings (3, 8,13, 14,15, 7, ‘37,48, 0,65, 68, 7,74, 76, 8} forthe teaded inet (2), ist housing (5), spool ave (12), rezze/ vate seat (16), containment ng (1), twine housing (52), ing goa (49), gearbox housing (68), Dearing tb (69) re-engage piston (79), and ve housing (1).SECTION 4.0 CLEANING AND INSPECTION 41 CLEANING ‘Degrease al metal parts oxcopt bearings andthe sater crv (7) using commercialy approved so} vents. Retorfo Table. Dry pars thoroughly CAUTION Never wash the starter dive (7) or shielded bear Inge (33, 82) n ceaing sovert. (lean alumieum parts using he clearing soliton per ‘able t;2oak ors minutes. Remove parts, se hot water, and dry oro. Ctean corroded see! part wih commercial ap- proved stpper. Clean conoded aluminum pars by cleaning as sated _bove and then inmersing the pars in acromio-i- TDI TURBOSTART TWo™ From TECH DEVELOPMENT We phospho act pickle soiton per Table 1. Rinse Inhot water and cry thorougiy. 42 INSPECTION Use Table 2s a guide to check for aceptabe conc tion ofthe pats sted (Check al threaded pars for galled, crossed, epped, cor broken treads Chock al pars for cracks, consion, itortion, or ing, or general damage (Chock the nazzes (16) for wear, chipping, or break: ‘age, especialy on the traling edges, (Check the spool valve (12) and valve seat nthe nor 2 (16 for wear. Chock al bearing bores for wear and scoring. Beating Dotes shale tee of scoring snes not o exceed 005" ‘width and 005" depth. (Chock gear teth for wear. H wears apparent, check (gear teeth mensions in accordance with Table 3, MATERIAL or COMPOUND (MANUFACTURER: ‘Degreasing Solvent (Tchorothyene) (ore ‘Commercial Avaliable ‘Rewtone ‘Commercial Avaiable ‘Numinum Cleaning Solaion| Diversey Corp, 212 W. Monroe, Chicwga, I 60606 Diesove 5 ox of Dvoreay 808 per ‘palo of water: Us a 195° 185" F ‘Soe Gieaner- Ros & Corson ‘Oat Prods Comp, 50 Vally Ra, Benet Hetgts. Ni 07902 Mir’ 5 bof Oukte Fast Stipper por (aton of wate use e600" F ‘Chrome Nive Phosphors Als Pia Solaion Mic of chrome aid, 1.9 gal of Phosphote acd 1.5 ga of nite acd fh enough water to make 10 ga materials and compounds. «WARNING» Follow all instructions provided with the above Table 1. Cleaning Materials and Compounds etn 45.725 Eon PeTDI TURBOSTART TWO™ fram TECH DEVELOPMENT INC. PART aaa ‘cHEcK FoR Detetve Parte Most Be ‘Sane te Gm | Wane ntarpersmeps | tag i = ecto ey | Cuando Sate noma tore cegenes | wwowneeneman | permeemumrge otcane un Stycast " Wortgesimcpetooes | semteomae Sang Guanes | Cased appt oramin | fiensalinrengieceatoew Perot Spmsienepe tae sae ‘wong Tabe Tea pa | Saae_natg geome pes | Tengen naieweatone Soe nm gran Sattcons prs ‘Rieter Sneiee Sete Rieaittapeon Sate Spon Tete tags | Gems eon tamanipn, | Hroriproecpiin ieee ‘Sconce ‘orca fey Sidogeue eaten Teme Stet Tpeem one | Werden teers ate oo | Soom Weare mt mow tees a Sites ‘ragga Ga | Peaninaten orion eeaatte aise gow Seerseamy 68 a capa Table 2. Pans inspection SECTION 5.0 ASSEMBLY 5. GENERAL ‘Aways press the inner race of bal earings when in staling onto a shat. Aways press the outer race of Dallbeangs when insaling toa housing, ‘Te rotor retention sew (26) must be replaces each time the trine rotor (28) removed Degrease all parts (EXCEPT BEARINGS) an clean Paes ‘umirum pats rferto Table 1 or dearing com- pounds. NOTE Tis recommendadio use HD S27/MS grease onal ‘gears and bearings inthe tutine housing and gear Eariersecions. Aetoshel #6 is recommended for ‘se on parts on the ouput side ofthe gearbox - ‘ve housing ar the sling Oings on tho pre-e. ‘gage pasion and spool valve. re-hbe al talonary ‘Seange wih Parker O-ring Lube orpevoleum alyTDI TURBOSTART TWo™ from TECH DEVELOPMENT ‘DIMENSIONS, PART DESCRIPTION = MAX ALLOWABLE. ‘WEAR Inches (timeters) es atinetrs) ner cea (48 in faoa-izou asus-asaig | 1300 sae Ouse Dame Sape 11) | ares seam osm es sag 2(s9 | eszn-asot (278-r270) | xno cee Tene Sr (39 ay oma. csnie.osts cases | ost casi sce Sag1 tert om tons damaerpe 1-1405 gocr-eamis | 1465 ean ‘scan 4082 «7 Ciena srs orzo | 116 ence I EAR ates socae pe soto-asee assets) | 362 ase ORT Ser ‘Showserrysomal-on. | x7aoxre7gasat-zaiiq | omar goo FeterSeateg wond-O9. | a747-07e (85-1854) are ase anes (at) freaPnson-sonet | aars.0sre (58-9559 oar! 55 see | osmes.essw cam. | ext car Table 2. Pans Dimensions CAUTION CAUTION “The bine housing Oving (97) must not be Wr ‘A screw treads are trated atthe tacory wah a ‘cated his tobe lstaloa ry. fastener etention compound. Every sore, 1/4 ch ameter or larger, must have a crop of Lote 280 ‘applied othe treads betore beng reused; screws — aaa ‘Saler than 1th damter must have a dop of Sexe et a bets shee ete ee ears For torque values, rter to Table tin 67 ont raeTDI TURBOSTART TWO™ from TECH DEVELOPMENT INC. Instalbe Ong cp (ero ne sc TORQUE soe trent Senge) PART DESCRIPTION reson sn (10 oot Oy ca (1). eingory | nm NOTE [Sern bie housing valve set (6) biked bid ‘Visually align the inlet housing (5) with the Saecanet Tense /vave sea Ce) sote pant sore at moo | we ‘et ave por wit sgn ne coas- tert ag (inte pope oven cerning onan (| sorH | me {or Raerte Daasersy Sesion). Roeser @e | —— Instant rosa (5) et the er Seca nesie or 8 199 vale seat (16). Push ogether to compress eee te sping (10: We hang nse poss oer tego aT ue Te | teaetbr tm up he fr cow hows an rome) SStinetve stone iho oo won| we NOTE eamrpepe em oi] a 7 - os is recommencdto atonal Sy ate moo | we {wo oppose evs, fo ecu sagt seats en Dui bore then a re ewe Ree ot ar =o zr ow tao pean TR] —— eg a Torque fe srs (1964 Lin (2 pene con ot oe scoaie ory 72 | Lube wan ovng ibe an instal te ving hooey (17) onto the containment ring (18). Table 4. Tove Valves ‘5.2 INLET HOUSING - NOZZLE / VALVE. SEAT ‘Lube wih Aeroshel #6 and instal te Ong () onto ‘he net housing (5). Lube with Aeroshel #6 and install the O-inge (19) and (14 onto the spool valve (12). Insta the shock dampener (9) nto the spe0 vate, Lube wih rng ube and isa the Oring (15) 06 ‘the nozzievave seat (16). {Lube the 1D ofthe the spool vale (12) andthe 10 of Push, by han, unt seated. Paget NOTE ‘Visual algnthe control ine access hole in the containment ing (16) with port inthe nozzle Seat (16). Refero isassemby Seeson (21). tis recommended to atomatey tighten two oppo: ste screws, to ensure a staight pul, tore iaen Ingalfour screws (7. Insta te inet hosing (5) onto the containment ng (18), instal he four screws (7) and torque to 14 Ft (3.2Nm), Lube with Ong ube anc instal he Ong (8) i the let housing (5). instal te int sent (2) 0 feet housing (5. stall the four screws (1) and toque to 25 LDP GAA Nm, Pte 4572, EtonNOTE “Aoply pipe tread ealan io fiings beers r-as- semby. Insta the long male elbow 6) it the por inthe ‘nozzle valve teat (16) and stl tho ale bow (21) ‘to the niet hous (6). Be sure to put these othe ‘ores pons. oer o Disassembly Secon (2.1), 53 TURBINE HOUSING Install the ip seal 31) onto the sea spacer (20) by ‘han, The fp onthe seal spacer (30) son the bot: ‘he seal ps (9) ace up. Pret he tp seal/ spacer assy no the tubing housing (32) unl seated. Relerto Figure 4 Inca the bl bearing (33) ro the tune housing Geyby har, tales nee Sine housing (82) to secure the bearing (33). CAUTION “Te tine hosing Oving (37) must ot be br ate, Ni 10 be reais ry. Install the Ong (37) rt the turbine housing (22). TDI TURBOSTART TWO” ‘from TECH DEVELOPMENT Insta tbe compression spring (95) It the turbine housing 22). NOTE “The compression sping 25) must be shoved past the O-ng (37) as far as possible ress the ball bearing (83 onto the turbine shal (8). Relerto Figes. Insta the bearing spacer (36) orto the turbine shaft 3). ‘race the urine housing (32) onto the turbine shat (08) ane press Io postion unl seated. Rete Fig: ues. Instal he "key (25) ito the turbine shat keyray eo. CAUTION. "Be sure to check tho rotation ofthe starter motor {and the correct insataon ofthe turbine oor (2). ‘Trin rotor buckets must ow inthe eame dee” tion asthe nezzles on the nozzle / valve sea (16, Be sure to check he algnment ofthe turbine rotor (28) ae key (2) re Figure 4 Iealing Turbine Housing Lp Seat ‘re 5, Insaling Turbine Sbat Ball Bearing Pap ttTDI TURBOSTART TWO™ From TECH DEVELOPMENT INC. + Use HD $277MS to ghtly grease the six rease cups (44), instal one grease cup (44) on each side ofthe tives gears (4) natal thea antsotaon rot pin (41) it the tree stage one planet gear shat (42). Tap the pins (41) Ino postion with maa hare Insert the thee gers (46) iro the stage one gear car- "er (47 and ag the shat bores. ‘and install the three gear shats (42) no the gear carer (7) and tap in poston. CAUTION £ 4 Figure 6. Instaling Turbine Shat Press the turbine oir (2) ono the turbine shat (28) ‘nt seated, Insta the rotor washer (27) and rotor retention screw (26) nto the turbine shat (8). Torque to 8 LEFL (153 NOTE “The gear shat (€2) must be lnsoried tom the sage one sun gear (38) ste of the gear car (47). Be sure aign Ne antvotaton pins on the ‘ear shats (2) wi he sos in the gear carr tn. ‘Set the planet gear shat retention plate (40) onthe ar carr (7, Be sue ropa tg eee Insta the thre stews (9); orque fo 4S Lb-n (5.3 Nim. CAUTION ‘Chock gear tation. The gears (46) must ate freely inthe gear caer (7 Wie eupgesteg that you hold he sun gear end ofthe {urine shat (8) n'a sfjawed (aluminum) vse whe orqueing he retor een sew (26) 5.4 STAGE ONE GEAR CARRIER Press he six neste bearings (45) if the thee stage ‘one panel gears (46). CAUTION ‘Presse bearings (4) Ito the gear (6) by presing one In fom each se ofthe goa. Press each bearing (45) fh wih the face of he gear (, Use HO 927MtS to grease he bearings (45) an fi ‘be grease reserves between tbe bearings. 5.5 GEARBOX - DRIVE HOUSING 55.1 Gearbox Housing Press the of impregnated bronze bearing (58) ito the beating nb (8) url seated. reas the fp sea (71) othe bearing hu (68) uh stated. Retro Figure. CAUTION ;Be sure that hep onthe sal (7) faces down no the hub (68). ‘be wih Ong ibe ae instal the Ong (68) to the recess onthe intemal fae ofthe gearbox housing (66) enn 2 tnFloure 7. lstaling Bearing Hub Lp Seat ‘Set the bearing hub (5) iro the gearbox housing. Take croton vp he four screw holes. {neta four screws (64) 10 secure the bearing hub; torque 64 Ln (7.2 Nm) CAUTION ‘Be sure 10 Fad the bearing hb (69) and the gear box housing (68) ily together whl irsaing the screws (6) inorder to prevent the Ong (68) om _shling out of positon. Le with Aeroshe #8 and ste Oving(70) onto ‘the bearing tub (6). ll the Ong (7) ro postion ‘onthe bearing hub 6). Lube with Aeresho #6 ad instal the O-fogs (74) and (75 onto he preengage piston (75). Use Aoroshol #8 grease the inside ofthe gearbox housing (8) andthe nie and uti of the pre-en- age piston (75) Hana press tho pre-engage psion (75) io the gear- box housing (8) and ote the Bewing Na (9). CAUTION “The more deeply recessed end of he pre-enga98 ‘ston (75) must be ted orto the bearing hub (6). tenon 5723 ton TDI TURBOSTART TW/o™ From TECH DEVELOPMENT ‘Sette gearbox housing (68) ai, 55.2 Carrir/Output Shaft Press the twee nee bearings (52) ash rt the tree stage two planet gears (3). “The bearings (52) Be cetain to press agains the at ond. Press. ‘bearing (52) Hush wih the face ofthe gear (3). Insta thee ant-otaton rol pins (4) nto tree stage ‘wo planet gar ghats (54). Tap the pins (4) topo Sion wih smal hammer. Place one of he gear spacers (51) on each sie of the stage two planet gears (5). Inset the tree goars (9), wih spacers (51), ito the (ear care (5) and aign ih sha bows, Hand instal the tree gear shat (54) ko the gear cae (55) and tap iro pstion. CAUTION “The gear shat (54) must be inserted rom he ot ul shat side fhe gear carver (55). Be sure to ‘ign the antsotaton pins onthe gear shat (4) wih the sts inthe goa ere (59). ‘Chock gear rotation . The goars (53) must tte frely nthe gear carer (55). ‘Set the magnet cap (5) onto the gar cartier 5). CAUTION “Te pon the magnet cap (56) fs over the mage ‘ete Froediod nthe gear carte (5). NOTE “The hve holes in the magnet cap (56) re not evenly spaced. Be sue to propery akg he cap (50) and he gear carer (55), Install ne tre screws (57 and torque o 45 Lin Ine.TDI TURBOSTART TWO™ From TECH DEVELOPMENT INC. NOTE Coat th bronze bearing (68) wih Aeroshel #5 grease Inset the seal postoning too, TDI Pt 46-25316, "trough hep ofthe seal (71). Insta the gearbox housing (65) ont he utp shat the gear earier 55). ‘wrt the gearbox hosing (66) n pace, remove the ‘s2alpostioning eo, TDIPIN45-25316, CAUTION ‘Wie handing the gearbox housing gear cartier, oot tthe gear ear (55) fa out othe gar tox housing (68) or you wit have fe repeat te pre- vous procedure on help seal (7. he pon the lpseal (7) Becomes reversed during asserty ot ‘he gearbox housing (65) ono the output shat (5), the ip sea (71) must be replaced. Hod the dive housing (8) fly again! he gearbox housing (68) and instal the wove srows (3) NOTE “Aig te ve housing (81) withthe gearbox hous {ng (06) 0 that component elertation Is corrector {al assomby and instalation. Refer to Disassem- ‘By Secon 2.1). NOTE Tis recormended to atematl tion two oppo: se screws to ensure astaightpul, belore ighten- ng altwelve sorws (83), CCaretuly tighten the twolve screws (88) fo ensure that the Oring (00) isnot out. Torque the Wve Serene (63) to 12 Lo-Ft (16.9 Nn. CAUTION Instat the tw thst washers (72) oro the out shat 5). Instat retainer ring (7) onto the output shat (5). ‘ncaa the bro sp ng (77 ona tha Be tre chive 0, Instat slater civ (7) ono the output shalt (55) andi the pre-engage ison (75). CAUTION ‘Check the ation ofthe gear carer / output hat (55), Te gear carer 65) and gears (53) stout all rotate reel 5.6 FINAL ASSEMBLY Sethe inlet housing - containment ing (5, 18) assem- Diy on the inet housing (6). Insta the turbine assembly (2 to the containment ing (18). NOTE “Ensure thatthe spt ings (77) remain in postion so thal he starter eve (78) seats te pre-engage ison (75). ‘Se the major componers must attach to each ‘ter, be sure fo align the components for both te oper general enentation andor screw hoes. Install the compression spring (7) onto the starter ive (78, Press he roller bearing (2) note ve housing (81) ‘nil seated. Use HO 8270S to grease the roter earng (2). Lube wit Aeroshet #6 arc instal the Ong (80) onto the de housing (8). Instat the ive housing (81) onto he output shat (5). ame Lae with O-ing ube and instal the O-rings (48, 50) ‘onto the rng gear (48). Insta he rng ge ‘he turine Rousing (3), Insta the wo shims (¢3) ono the sun gear pn of he sage one gear eae (7), One shim 23) goes on| ‘each end.NOTE ‘You can use HO S27IMS grease to hold hese tims (43) m postion dung assy. CAUTION Use HO 9278iS wo toeraly grease the ineror of the ring ger (4), the stage one gear carer sec- ‘ond sage sun gear (67) ane the stage two gear car- ser (5) Insta ihe stage one gear carr (47) nto the ring gear (49) and onto the tutaine chat un gear (28). Rotate {he cai (7) uni uy soatod natal the gearbox housing - gear cartier (68,55) oto the rng gear (49) and ono te sun gear ofthe car (4). Peta uly seat, NOTE Recheck component oferation and ser hole aigrrent Insta the fou screws (67) to secure the gearbox ‘housing (66) through othe eorainent ing (18). NOTE "tls recommended to aerate tighten two oppo- se serews, to ensure asaigh pul, bolo ighten- Ing alfour screws (67 ‘Carty ohten the four sores (67) 10 ensure tat the O-rings (48, 50 on the ing gear (49) are not et. “Torque the four serows (67) 1014 Li-Ft (19.2 Nm. the sic crews (23). Torque the sx screws (25) 1045 bing Hm, TDI TURBOSTART TWO™ From TECH DEVELOPMENT Inet ine controler module (60) no the gearbox housing (28). CAUTION "Ensure alte speed sensor probe on fs contro. er mode (60) seats ete Courorbore the ‘gearbox haveing (66. Inet tne seven screws (61) 10 secure the controler ‘module (60), Torque fo 15 bin (1.69 Nm). ‘Lube wih Ong ube ae instal the Ong (65) onto the gearbox housing (68). Sethe solenoid var (3) ‘onto the gearbox housing (66) and secure wit he three screws (62). Torque to 64 Lb-n (7.2 Install he ho male elbows (21). One goes no the ‘gearbox housing (66) and one goes ino the solenoid valve (63) NOTE "Rope thread salar ngs belore reat seme. {ntl hone 10 solenoid hose (59) and he ptomto- valve hoes (20), he theeaded inet (2A) i used instal he Ong (3) Int te treaded inet (2A), Set the threaded et (24) ‘ro the tha ret Rous (5) and tal he fur screws (1). Torque to 70 Lb-F (949 Nim), tach he solnoi ead othe controle mod (60) terminal stip screws marked SOL. Thee leno pos te or negative for thase lacs, WARNING "Reiorto the Wedel 45M instalation and Operaing Manual for completa intataton iantons ‘ein. PatsTDI TURBOSTART TWO™ Fram TECH DEVELOPMENT INC. SECTION 6.0 TROUBLE SHOOTING GUIDE TROUBLE PROBABLE CAUSE ‘SOLUTION Te aworsto sop | A Seabee c | A Ga nape womb a get tate Saree oel eg. 3 Samaniego, "Gecko pt az mnie pad co son tt oe bow Ch ne ren ‘Soo teen Ns COM eect an ok Srpterimny, ect oss ‘Soloncg Yori eae spe 200. Gch names er oid ae 7 law et Repose cna nie | 8 Cec canon Fong se ao ey ponte rth econ ‘Forwinamicermeais |. Gmdvaage pada dp sa Sie en ene Se aoc aterpomert paises rt ‘Sen sant ron ee rl, ep 2 Socisatacetepe tetera see Ne ‘Sona tos covey Se mee 1 Aipesom aa picn | pda ier Ops areal ec Sect sures sen cpeon Chao ttc nat 3 Sew aeetacroral | A Bain baimaee 7 epee nH ep ne ‘engrafted Eliepes ten ante mae cr T Ganson amg ngerian | & Rar ore 7 Seon amie | A labia Teepe alte RIS OP Sonora aat 3 Ente bnpenr 3 Rennie voor © Dood tire tee © ep ncte ei Sool Bena 7 ap oma 1 tarps XS ow 3 Vawter a TK Bremen wen 7, Sate ae ota apa ‘onoge Rept poet eS pando attend a doopeinon ee ee system components. “), + Asie eng rato! eng is cbnged oh ad erates, the power pon operates to change fel ‘heron valine that ine, te compensate po lo operates se rulanece, bu 2 pressure generate tempor in Se compensator es. Tis peste ain be reverse rectiontothe movement of power pon anit valve and tus ass in ely esering teed sree serine ie Ber u > Tri te [ae [Compessarene | Pose | Neg Picravetoereue | pene | pete overaing | Unpren [mpm ving | Comper | etepeae 1+ The maguine of postive ornepive presi ofthe compensator as an lt valve lower cae may vary according to the opeing of he este valve andre ures a proper ado! fthe opening. CD se 35. Adjustment of Needle Valve Ifthe needle vai ltd oo fly te govemor ‘becomes dll andthe respons byte engine delayed In load Mactuaton. Moreover, if opened 0 ext sively the engine oto besos ensteady. Fea@Nz GovenNon CHAPTER 3. MAINTENANCE INSPECTION ‘This Chapter describes the tine maintenance inspection, asi ajusment nd rovbleshouing ofthe governor. 341, Daily Inspection 1 Inspection prior tostarting (Once aay check te oil level ofthe ol supe, The specified ci evelisalevel2103 mm above thecenter oft sage. + Inthecase wheel lvel fal, eck there is sncilesiage 2) Check for loosenes of tots and mats of vaso pats snd if tere is an abnormality of linkage which comet the gover wth fel jection pap. 2) Inspection during + ran (0) Measure tmperture ofthe gover housing with of terete ‘Thetumperanre becomes able ifthe engines rn for 30% 40 mints, + te temperance sso shove 0°, there willbe sn sbnormaliy. Tha, make a check. (2) Check fer any sbnomal nie. 13.2. Change of Hydraulic O11 ‘Change te hyiule ol fet in 1,000 hours or tee ‘months and subsequently in 3,000 hous or every six mouths wih the new oe. ‘Anll volume o each the specified oi lel is abot 13 ng the Bydraul starvstop leer of the engine stn the STOP pos tion so as otto start he engine by make, cit, have the’ a@ Nz GOVERNOR (© Desch the dain plugs and needle valve fom the _poveror base to charge the oll hyo ‘Detach the needle valve only ater checking I retin, Rs poston opened from ls completely eed state by how many tara. (© Detach te cover, and check fudge is ecumlated inthe govemoroll sump. (© Arach the daa plugs and nee vale, pour in the ew yale ind amc th eave. 3.3, Air Bleeding of Hydraulic Oil Passage ‘Bleed he arm he cei passage secrding to ‘he following procedures: (1) Sete needle valve inthe fly opened sing (hee tu bck tom the completly ocd st). (2) Tam he cote nb oot the speed con haf primer withthe SPEED graduation 0, and star the cegine @) Rune engineat alow pedo thuningor surging, sedi frber for sb! 5 second. Stomly close the net valet stitin te specified pesiton 1 Incze wher Beeding i suit, tng may not be stopped, In tht asi ope the nedle ‘valve again wo ethan 1+ Whenever the gover Is replaced, serviced or ep aj te ned vale. Di sec... Adjustment of Needle Valve (6) tn ee where the ll level drops, fd the governor with dai. Fess34. Speed Droop Adjustment Adjust he speed opto change acorn othe fol lowing proce: (1) Remove the Cooler) cover, and change the set poston of he éroop ads. As the aduser graduation i sited inthe “0 rein, th speed oop lessens. As the ater gradusion shied in the “10 rection he speed droop enlarges, (2) Asach he cover ruth engine and while measuring ‘the sped too, change the st potion of the droop adjuster wl te aimed sped crop ie ech “Bach ine test poston of the doop adjuster is changed eau the needle valve, 3.8, Adjustment of Needle Valve ‘Te needle vale Sens to adjust the respansecharac- ‘erties ofthe governor. Ifthe esd valve is property used he engne malin the fe inecon vole after achung aod we the mnimom retain Mers- ‘hn an ine. “The nese vale hs been aust of with the engine individual Ihe following cases, the neal valve has tobe ajc + Incase ware te govemor i repced or ervicd + Tnewewre te govenorisovetaued (sss at and epic), ‘+ When he visasy ofhyauiolischanged + Incase wht inkage which comers the gover: se wth ft neon pump i akere. ‘+ ice wher the set poston ofthe oop auster ‘seh, (0) Aftertearleting ofthe goverorandsening ofthe oop adjuster ae finished, rn the engin a wel 5 the govemer unl hey asume the waa rnning ate, ‘Aste engi sun athe no-load rated spot for 30 w 40 mises, the viscosity of bya oi sabi athe weal running state, @Nz GoveRNoR Roop ADJUSTER (2) Seethenediovaeinthe wie opened state posible within arange te engine can run wih sendy areca 1 Incase of seers diving, 2 the needle valve under the ated sped ate of te eain, “+ nas aman marine cain or ving pump, fer instance, se the nedle valve under he mini ‘mum sedate ofthe engine win its normal service ngs. neelevalveisclosed to firmly, the governor becomes dull and the engine's respons t ond ange delayed@ nz GOVERNOR 346, Cautions in Initia! Run. tn be shipeag of your engin from usp, the goverar ar been aj and ed with hyalicci. However nase ner the soveror is plc, servi rrepie, ober he following mars in he i 1) Mounting of the governor Wile seing te governor with plo of the ea shat, rmoanthe goveror under its on weigh. 2) Oi feding (0) Feed he governor with new hydric. level2 to3 mm above he camer ofthe ol age. (2) Moe the govemor vetlel the termina! em eco hey, and Bled hes om the power son an yar pasa. (9) ete lee cope, replenish be hydra ol p> ‘berpeifed level 3) Connection of the inkage ‘check ia linkage which connects the gover witha fol injction pamp hat been ted propery. A poor connection ofthe linkage Bara pesibiity of bring elated abrupt rotation ofthe engine. (0) Se the sat lever ofthe engine In the STOP peiton (2) Fie up veto the terminal sha ofthe gover- and onset inkage. (6) Tete emia sat fully into FUEL gadatin 0 Greco, an secarely ttn te camping bot ofthe oat lve + Teteminl haf pointer shold nice the“ + Toerack of fet injection pup shoul be inthe revnecon poston. (Shit he saritop lever ofthe eine athe RUN in, ad ten check If he ouput leer moves Tight when ti hile fom te 0" 10°F" terminal shaft gdeation4) Setting of speed droop Sethe droop adjuster cation ofthe new or serviced soveror as ben enh temporary tthe 0p djs refering othe former gover rth adeter sredation prio the rep. 5) Seung of he controle “Ture conrlinob seth sped consol shat poier inthe SPEED prtuasion "0 ©) Startiheengne according to Operation Mansalfor teense, ‘Be sare Sart the ean on the engine side, and have it ready so hat ean be topped at once ‘Should abrapt rotation break ot there i poss bili of maging the agie or causing an accident seing in injory ode, 1) Adjustment ofthe drop adjester and needle valve Adjsthe coop adjuster and ned valve CDi sec. 3.4. speed Droop Adjustment CD sec.3-5, Adjustment otNedte Vatve @ Nz GOVERNOR@ Nz GOVERNOR 3-7, Troubleshooting ‘Aveouble ofthe governor ormally appear a8 speed chang ofthe engine, be ts practi impose erect al nd of wables. Thir Caper outies the most gene roubles ofthe governor. Annee edn ustisctory enol are cater by awoble onthe ngne side or aroble ote gvear cr conmolle Since the governor sess lagen earetsles agentor service gent (sown int {othistncine operation Manual for repair of your governor (aE er of precios part sevice network here ina danger ooverrunning the engine Ifpart are nrongly incorporated or eftingsimproperty done, dost repal the governor in the eld, Det const our “VANMAR Worldwide Service appended Sidley = 4 —— SS Lerman Sas — Ra a | Ramo Fo rg re — Se ager pores Slike | Geacca —) omiemoes Aiimnel ecto Fiesta Re pens Serene come foeo oe = oo ——™—— cre woos f tes | Eeercome| Sones eee Se ees —— —-= a ey poe ae eae a Eee, | Rianne. [owned mntommnas ete, | See npone Romana foams fosaaee | (eee Poonam ihaes _compensetor mechanism | vanes pare depp Se rena eae Qatteeee sfbysa a poop ee oolre) [Prssue reuining ane Oven oie TB Conti} |. Pros ached igen etn TPreanasConsie} ‘fete dimen Leap sraconareee arodmatinciond _|¢ Coneioncltvep [Rena Cone |. Barter comiag [+ Coptngcorecio of enon} tole courte iisopea | Scitant than eter |e Sevag ices |, Femeat set maicines + Sevcing Pd@ Nz GOVERNOR Noe ool an Ge oo Gover or Se [senna iin ache oven [> Coven poor mau Gag ysem gerco |” (Ge satand pe coopng ite footy cones Ieee tyson Repacafagoe wean. [Nowapafontegom f toi os a FGovemar weigh calcio Spine gorenae > Boverpaon sa veg deve womctt |" [Ope oe gover nt lage sac fuel) Gaputiercanss + Freres rive suck ‘Over ng ereplce . + Sitenmmceotaerunp as |+ Suc casing ese olsre (poco oe par [Sovenormae ace ‘Oise eanagatr Ua Relea of ec seal or@ Nz GOVERNOR [34 Criteria on Parts Replacement ‘Observe the lowing rer for replacement of governor prs: ‘Nurs lise below refer tothe coresponding mbes ven inte Development Fig. Reyacone anal Pan Destin No ov sven snnenb 2p [PACKING evens ms. 5 : Jerevey 10000 [RACKING gover mig ‘ ' PACKING, press. euaingvave pe 86 1 PACKING, bene it 2 3 PACKING, soppertt 2 1 PACKING, dain pug se 2 PACKING, presse resting abe 6 ' RE, fosting ier 2 2 SPRING PIN foe 0 1 [corner os a ‘ low SEAL, bee 2 1 [ORIG compensa os 2 (ono, mae 6 1 [RING eae ahe a ' lsersyrs. ores. [GEAR SHAFT ‘ 1 }seEDLE BEARNG 1 [rsmusr wasteR 1 loupe LevER > 2 a [ot SEAL, emit apd conc shat i ‘ Iroarme eve a ' low cauce 6 : jooveRon WaIGiT Ass. “ 1 |pReSSURE REGULATING VALVE ASSY. e 1 ‘NOTES: (0) Replace ao prs ote than te afereetaned with he new ne ifthe Wear, flaw ras te found asa esa of vera inspesicn. (2) Ase geal rae, replce hoe pars usd or thn year or 000 ours byte gover atenby@Nz Governor CHAPTER 4. REMOTE CONTROLLER ‘One oftire type of remote conrolrs sable fer remote coal ofthe governor is gupped io 2 NZ Series Goveroe scoring othe specified specfeaon, (Fig. 4 shows the appearances of govemorsequlppe withthe espetve remote conlles) ‘This Chapter describes he peratin and maintenance ofthe respective emote conlles weroncommousn] [wewanccommousn] [ne conrnoua Siatancfeme caso eeoyase ic} Fie +@ Nz GOVERNOR 41, Motor Controller Changing te compression of te governor spring by 10 tinofamotr the econo ststhe govern any ogine spent. A mot eqpped isa reversible, single se moter. Tate case ofrguningthesoueamanoally regulate iby mar of the coma eb. Bese, te motor cool ofschaspecfeaton equip- ing nt we tthe upper and aver iis of te ‘ngs seneleciely sas avaible 1) Regulation othe spent + Therotortu wilh pend eng switchs being ped onthe remot coal ie, ‘Tiron deeleraedby the gearhead rasmied totheferkofthe governor tought clon coupling ‘orga, bevel ge and pode see and changes the compression ofthe gvera spring repute the ge soe, Mon Sigh Gaee + ty the case of mans! requation, ing the col nc intermeshs the manasa sear with he motor ‘rarsottatthe roo sansmited the govern the same route a inthe case of motor ting (remote cared, Besides, athe the contol abs tue rng remote centre traning he tion uch often coupling sips, inparing no sere effets onthe ar ead nd mote2) Adjusmen of he iit wth ‘Toelinit switch arn rough ashibaed onthe sew secon of limiter incorporate to te manal sha. The opper and lower inks of the engine seed a st by sausing the postion ofthe limits though shit of ‘he iter by turing the como ob. ‘When working on thisadjstment eithercat ofthe ower or cover the capacitor with inculator. you happen to touch theresa pes. etic shock ora fire caused by short. (© Loosen te iit sich adjusting Bl, and shit te int switch inthe recon of an logit ae ofthe Timi ow guide to adjust he wich positon. 53) Blt ounetion of he or controler Coens the mot contlle as shown in Fig. 44a the moter sa single pase moar aval ia two Opes of volage, 110Vand220V. As viewed fom he gearhead sie, the sas of tation of the moor isa follows with spect he rotation of the sagine: + Inacederaon: Clockwise + In deceleration: Counterlockvie @Nz Governor Fees BATEDPOweR | APPLICABLE cAPAcTOR Se Sieney Sar ee AcReOY Gs@Nz GOVERNOR 4-2, Pneumatic Controller “Te compre raving he specified prestae i sem Inthe ono by ema corel ‘Tepresur ofthe sr acedon he phragm swans ted the governor sein ous he piston and spindle to change the engine RPM. “Te ngae RPM can be changed inthe same way a5 by ‘becomes aby ming the ono ab 1) Maintenance of he ostroier Repae the Oring @ and dapiagm © of te corolercap@ withthe new nesbieaallyorevey 9g00 hors even fac damaged Wher cimstembing he eumati consol, refer tohe Development in Fig. 410 sad the following procedures: ‘An eal numeral appended «pu desertion 9- ering inthe following tex refer to he eomespnding uel given in Fig. 10, Developmen (a) Deeb he competed inet ple, owen he lock handle @ of he convler, and loosen lo te eal kab @ aia ily. (2) Lown he clamping boks ®@ andeeuereus @ of she cap © wit ee ofeach an Philips ee iver snd remove be ap See Fae 66(0) Take out the iphagm assembly, and semove the rings @ mdspines @ & @ (4 Lig inser te with aros as of te Hp of he ps od @ ina vee stand, loosen the at @ , and then ake owt the upper pte @ ,dlapragm © and ison @. Nz GoveRNoR Disasembly of major pars ofthe pnesmatic con- troller i ended with the aforementioned, Disa semble other pars whe and ifneded. 2) Reassemblethe pneumatic controler in therevere sequenceofthesorementoned disassembling pro- Jn this Subsection, casos to be taken in rexseing sree fr (0) lneorportethe pertinent pans (pashaving stered reference number a Fig. +10) upon costing tefl lowing spots with lydenum uid: + Outer periphery ofthe aut screw @ , + Both faces of ering eat @ nd + (lommé) shat pat oft pushrod @, (2) Pay your eneton tothe following pins whe incor- eaigtedaprg: + Coat he base vic side ofthe dah with molecu due + Parle the wit across Das of the tip ofthe push od wi the Boag lever ofthe over ad then ‘mount the diaphragm on the cylinder ©, + Set the promsion onthe outer periphery of the apap nthe prove ofthe ying: ©, 1+ Making sure hres no tet or wile othe Saphragn, then he ap ©. + Dow'ughen te nat @ excessively. (robe este costes) Sines Fig 69@Nz GoveRNOR Development & Nomencatare ofthe Peumatie Contra “NOTE: incorporate this part upon coating wth seizure inhibtor (molydenu eu). Fig 410 Ne, PDecipon ey pe PaDeaipion oy 7 [BOLT mx sine 1 _[ fasts 7 2 [NUT ce 1 | a8 [PLATE per 1 5 fo coaet 1 | is fast srg + 4 coven 1] 20 lpncsees 1 5 [evnber 1 [it [Pack coer t 6 lou 1 [2 loans ' 5 Jotaramaom 1 | [pourasxan eter 4 5 |r, pu 1 [24 pour exes 2 5 |ADIUSTER sping 1 [2s [scaew sxis, 3 10 [NUT os 1 | 2s [scuew eas, 2 1 | SPRING, phragm ou) 1 | 2 [prin 1 12 | SPRING, doptapm Ceo) 1 | front miei 1 13 [Sear gr 2 | [oocr peat 1 14 (scm she | 5 Jeacxane 2 15 [HANDLE ok '43. ‘Wit a lever ached to the speed cone! sha of he goveroy,the wie courller repulse the engin ration, ‘Moreover, ting the como knob can also change the engne spin he sameway asthe contol able ire Controller @Nz GOVERNOR Development & Nomenclature ofthe Wire Controller Iso, mex [BOL mas tn eg leoven 0, cone wor, ek PACKING jpour Fee Ne Pa Desipon ey [re TeDacinn oe BREEDER ASSY, fle po combined 7 | SeREW hae lpackiv,mtter 4 | Screw, euae 3@ Nz GoveRNoR CHAPTER 5. DISASSEMBLY & REASSEMBLY OF Bi secre asi le) 3 541. Cautions in Disassembly/Reassembly (0) Donot“sasseble the governor necessary except in the cao specie, (2) Inthe ease of repair, hav the replacement prea in advance (6) Friorto the dsasemby, ae th governor performance an is adjusting spt pt on recorded ‘Compvigtheajusing values before and after tbe dissenly makes ety ond ou the case of rouble 1 Speed op + Droop sje st gration + Adjsing value fete valve + Tema! sat potter graduation + Speedcanzo shat poster gation + Have a linkage coaectth erin! sha wt the fil nection pum given With he set mack (6 When taking oat th gover and afters removed, ay you tention not impart shock to he emia ha, ‘7d conoo shaft snd gw shat, (Sich a shock:ny cane a bend ofthe shal, pina deviation of aa sh ora damage of nema pas) (©) Aferthe governors removed, cover itso at dst ne favign mane wil tent the governor delving device. (©) Before dasembling he gover, ean ts exert geri of adhering dst ee. (0) Keep a desembling workbench cen, and ut clean light for cleaning fi. (8) The folowing tools ae nteesary fr dasembly & ressenby ofthe govemor: Teal Deine plan 1 Bnei st [ew Gre than i) ain Stig Oe Gm owe Fr deting ing per = We an wares) [ing ce Ba rene tm witty [FS Stine eating he ree eng 8 = [reaming encore a 4 i a Seen te Fras ere a ecw i Sma wianoy ee = sc ricci legen ig cng le se @ Esco ny ahem) rain eae I = (9) Be sre wo change cone ns, ring pis, wire, copper packings and other packings withthe respective new one at tine of deeb Refer Caper’ fr prolly replacing par CD crapter, Sec 38. Criteria on Parts Replacement a@ Nz GOVERNOR 5.2, Development of the Governor.(Soveraor Part List @ Nz GOVERNOR Ws Pas Darian ey | ¥ PetDacipon oy 1 fuousnee 1 | 57 [orne.mastevne ' 2 Jose 1 | 38 |ranercaTe 1 3 |seaLot 1 | 39 |aMerLare. Lesa 1 6 |surr se 1 | 40 [NAMEPLATE Rides 1 5 [PACKING te 1 | at [vanveassy. pase 1 6 PACKING cover 1 | aut [aus piacvave o 7 |BeARING, ene 1 | a2 |vatve pice ” 8 waster, tose 1 | @ |vatve seat ' 9 |seRmc coven 1 | |vaive prareresusng ' 10 [rons ne 1 | 04 leony o 10 |eeven suis 2 | «2 Jpistow o 12 ov goiter 2 | 63 fre o 15 [aR seri 1 | 4 foo o 1¢ | SHAFT, emiatoape 2 | 2s [pm o 15 [ADIUSTER coop 1 | a6 fracas ° 16 [seat 4 | 44 [wero assy, gover 1 7 fous 4 | 4s [waster ceopsdjcer ' 18 | sHAeT, spent cons 1 | a6 waster, rep aust ' 18 {cour 2 | 47 |RING. cooper loner sing ap ' 20 ron 1 | ot |e emi em ape 2 24 (LEVER towing 1 | 9 [PD commoner risen ing 1 2 fone 2 | 50. pm toe 1 2 fronerr 4 | st fr ui ter pincer 4 24 |semmic 1 | 32 paCKING tse neering tt 3 25 |storrer 1 | 33 |PacKmic.soppertot 1 26 [ave ou 1 | 34 |pacemc,cain pig 2 27 BUS compat 1 | ss |rvoaam 2 28 |ISTON, compere 1 | 36 |packmc esa repiting abe ' 29, |srRNG comprare 1 | 57 |peAnmc sede ' 50 |R00, comps 1 | 8 |B0LT, metering he aac 3 31 [sta canpnatrerpr 1 | 9 |screw pner 2 32 |PsTON poner 1 |e four. poste 2 3 [SPACER compere ing 1 | 61 |ScREW, oop aser ' o |SEAT. sping 2 |e |serscrEW, mint am tex sce 2 35. [AIG conpensor bah 2 36 [oan tue 1@ Nz GOVERNOR 15.3. Disassembly ofthe Governor Inte of isaeemblng (or reasembling) he gover, refer to Fig, 5, the Devlopes andthe flowing proven: aa eacled manera given in igure of tis Caper ofthat appended 2 par desrpson appearing inthe lowing ext refrstotheeonespontng numer given in Fig $1, Development. 1) Loosen four cover clamping bos witheseofa wrench ving. 10 mm with across las, and remove them toga wih pakigs®. 2) Tum the gover pide don to dschuze the hy- rio. 3) Remove a dala plug on he oi gauge sie fromthe tase and ine the bse at the vce sad for ‘ing 4) Staite wi pie oe side of vo wire: @ that ‘se coupling te fang ver @ Replace the wires @ withthe new ons when reassembling the goveoor. 5) Holding the spring fk ©, eke cut te gover spring © together wi eile valve G3) ‘ot removed from the plot valve, soak them it ean ight i. (@) When taking out the plot valve, pay your a= tention not to ae the thrust eating © and ‘hrst washer @ that might fl ot together.1) Draw out the coer plas from he pute lver Pins @ thatweeosping te tenia am @ with the power piston @ , and remove the guide levers © sd guide ieverpis @ ‘+ When drawing out the gue lever pins, be care {uno tse the com and spring sats @ ‘When placing the governor upside down pay your sttention not t lose the thrust bearing © and trust washer @ in cate they are stl remaining Inside the governor weight assembly. resi @Nz GOVERNOR ©) Teptheside ofthe bse © with a pla hamner (or salle) ndash dpned from thehousing ©, raise the base sigh upto remove [As the bse is emoved remove he nestle vaie @ fom the base with se of blade sxewervet@Nz GOVERNOR 9) Remove te ile valve busing Gand gear shalt © from the housing and bse espe “Temporarily ressmble the removed lot valve bushing with already removed pit valve and soak ‘them in clean ight 10) Push down the power piso below tbe gover upper bar and remove tips together with te compen saartih @ 1) Usagan cena, aw out springy @ inside ne govenor, and remove the speed contol shaft Gicolar @ fork @ mdspene @ ‘+ Draw out the speed control shaft asthe pointer & eptintct on the stat “+ Whea drawing ot the spring pl, pay your at- tenon that the peed contol shat would not bend. + Be careful otto Maw the mating surfaces of the12) Unscrew he stapperbokt @,andremove the gover oreigh sembly @ 1 te hs Searing, @ and srt water © are rams inside he sembly remove them fom 15) Dissembly ofthe ein sha it ‘Do not dasemble the termina shaft wit uoless ‘he termina sat operates unsmoot ors parts ave tobe replaced. Wen repli prs ofthe terminal shun, laser ‘eis uit cern tothe following proces: (0) Tum he terminal arm @ aif sound and hammer themineedimetr sie of uperpin @ toremove (©) Using bexagonal wrench key Qaving 3 mm width ross as), mere the sewcrns ©) Draw ou he emia sha @ , and remove the seminal am, When repo Fm, be sure to replace thea asset since they have been taper bored topeter @Nz GoveRNoR© NZ GOVERNOR 14 Using 2 wrench having 24mm width arss Aas, removethe resirerpulasng valve sembly @ isusambly of jor par ofthe governors ended with the sforemestond, Diestemble ober pans when snd if eed amare s@Nz GOVERNOR 5-4. Checking of Various Parts 1 Clan ‘+ Clean wash) te csasembied pans in clean leting fi ight i, + During lessng py your tention not o impr hit mars partly wo he lot valve, pt vale bushing, power Piston, ne bearing, hs athe. + ther wip te cleaned prs witha lan lt bow the dys against hem td ther. ‘+ Check ifthe oes fr hye ol passage tebe nd housing have been leaned neat 2) Parts check + Check cach par or eck, damage an ast and if found deecive, corer replace such past + Aows ive inte flowing gues refer to check pois, ) Base [Replace thse gx shat nd pit vale bushing hat haveserchorsding aw oc hitman ace athe gsr ‘eg with Be new soe, Fess 2) Howsing Replace toe gear hf an pl valve bashing ‘hathave fiw ath ger ali part ortose power ison nd plot valve bushing that ave 3 fw st the fning ole with he new one Replace thse tamil shai and speed conto! shat of which bearing bushes @ tum se ied ‘ooely or are wor fy te housing ase.@ Nz GOVERNOR (9) Gear shat an pit ave bashing Replte the gears ofwniehoisealcomstng pat le wom off repped o f which he pie pis dacnaged and pt wae bushing of which the outer inmeter (18 mn) is faved with he ew one. Be- en sie, replace lo tae pars of which ch surace 5 1s awed wit the ne ones ‘Check abo whether the spline file onthe gover — or driving device sie aboormally worn off or Fig 515 (@ Governor weight sembly 1+ Check ifthe governor weight moves moot + Check the ace ing With thst washer a he swipe part Ifthe bexsing width found tobe _gowerthan | mim replace byte weihr ase My. ‘+ Check hare Sing with he lt ve buing is scot, + thee sa hitmark, bar ec, cnet sich pa, (5) Power piston and compensator pisos Inexeporme th pow piso inthe sao norpo- ‘ang the compen pion @ and compenstr ashing @ ) inthe beusing. and check ifthe power son operates vereall under is own elt More- over incorporate the ype spring @, sprngseats ted guide lever pine inthe power pon; and heck atthe compesntor piston moves smoothly. IF cpernionsfhepoverpto and cmpenstor pion sce enrowth nd ono improve even arth re leaned lace the omer pisonandcompecstrrod ® operation ofthe power piston and compensator Piston ate found bad, hi causes a hunting, ence ‘ve sped droop or bd condition inthe engine ran(6) Gide vers and sped control shat Replace be guide eves @ steminal am of which 8 ming hole the sie lever ins @ is corse wom off wih the new ons. Besides, replace the spend conl sat @ which is found ba othe shat spporting pars or bushes @ sre fund worn of wit the new ot (© Pressure reguatig ae Deve log Gk urbe pring Gand check ite pisos G3 opis snowy. Is persons fond xh rite offecenly, cost or replace it @Nz GOVERNOR Fie 19@ Nz GOVERNOR 5.5, Reassembly of the Governor + Ressrbiethegoverar inthe reverse sequence of he sferemenaned dsasembling procedures + Inte Sebsecin, oon 1 be ken in esebhy ofthe gover arse fh, + Replace the Oring, cour Pins, sing pas and pack ings with the respectively new oes, ot wing them ain 1) Oitseat and neat bearing (1 When peeing eo seal ©, be careful fis frig entation (in which donor make a mistake). (2) Ween pes ining the needle baring @ , poston onthe end ofthe ol se ting hoe re nel bearing pres Sed excesively, this wl ack up the hydral o passage 2) Incorporation of the trmiea shafts Inthe ae whee he trial sats re Gissembled or replaced withthe ne cos, incorporate them eroding the folowing procedures: (1) When driving ia be taper pins: @, bol be emia sm @ by band and be carta atto para shook toa bush pres feed the housing (2) Afer driving nthe aperpins, cat ourpints around ‘ape in oles ‘taper pn driving in and cain ae, strong fore the terminal shafts @ may bs cae them to malfunctions pay Your ats ‘ono his regard. sn23) Incorporation of the fork When incorforsing he fork tothe speed convot shaft @ ise the spring pin @_ withthe sepped part ofthe fork feed up, 4) Stopping wire from tipping ost Aer ncrporsing two wires couple he fake @_ wit >>) the oatng ver aswel as thesia fk ®, bend the eadsofiee wires for oping them om ping cat of plce ‘Bend about 10mm ofthe straight partof wire in 30 to 30 derees. Round the bend tthe smallest ossibe rads the bending angle o rounding i are this may ‘cause malfunction ofthe foating leer 5) Incorporate base When cope te bse ikenbos @ i Seay ony eight tgs @ ca be yee me Tf the gear ht conld ot be ane ht by and, ote ha hs igh damage the yea ol pump bas 513 @ nz Governor Fie 53@ NZ GOVERNOR 5-6, Service Dats in Servicing “This Seston st fort te ating (confirming) ems athe tes san inne of enc the governor a flows Sette following ems with he evo duster se 10 graduation (Pay your ateon otha he drop ae does ot contact waht sie fhe Seating ever) “+ Make te lowing adjrrmens (ecudng No 10 No) withthe nese valve fully opened eo open a pstion 3 rt back am the comple lsd poston) 1 [vaca |. sazxo Otome: ABC Onengerre S5BEC 7 Neming fe gover” [> Pong you esting ia se (hv or ecard en ing os |, rune come eer ancheve contained | (ey | 7 [sien am Gover are .000210 mia") vere oe pce tc aca power 1 [Renee [> Sine gnemar unde Noma fr20 mins ad ck | Satro tera sinking eee (Gust rhe iene bmp ine of he oi espe) [ering emia (ovenar apa 1600210 mis "URSD Seppe aint ine 7 [eietngtteroninn > Goer apne 600210 min" "oe=) age often aks [+ Whore pr coal arenes + and dine te ‘etal sat hols pomp an pete ove lee | SGGeFUEL pedo | tmneina Noa Nos FUSL puatnnns D107 (035 ep) emise-onss) Nas) FUEL patatow “DOE (%8 cep) ema (NES: FUEL gration "011009 Oden) once ee 010 min) teerunet 200m \ \ |" Getencaltnatomts on puto eb FUEL cand” gemgiore™ | eins Iescios fre ie = | “eee ] fe [fessor Motel ra Nagin) ‘agin Mol? a THEE —ieranaiae ST] | temeocms) t TTS retIii2) | tomnewets Sais) — teens si pein oc erent || shee vere sconeorecton || o Thecewne of rere td sg ge | = Ince poner me campse ot weime | Jo Seca of byenary eu ee | o Foran nce teow oe ure | fo Preach pis ang boing | ore@ Nz GOVERNOR The Poirecsues Fame prescott (covorapeet 2000210 min p=) Towing FUEL pata “ Nasi FUEL Nast: FUEL nan FUL Sette oped aol hl inert he flowing SPEED ti nd genes 26: SPEED 10 NZILS: SPEED “107 soe nose) ‘emiee.ones} (emsiera agian en) (Grooves) [evens fe 0 pat [+ Lovee govenar oped be No.8 ee Ha ee] Sta poser smer fling FUEL pasion Nest FuELe Nasi: FUEL naus Fuck (Chek eerie sped sel sha pointe be Zs $6010 790 mia) NOS: 40012600 mi" pm) ‘Sli he governor cpa nn oo ee renetane a |o cacting ane rp atin pada, [2 Pena enn fe seed cs sa pn, (2 insporson oe prec rn. [2 Govenor weipasensy, (eoeine nota) feme.e Inyo ini io he = Govnor apo 00= 10 mpm) Sere temina sat poster she FUEL“ (js sein by tng snob) + Mente rece aes cane ote cmpesy ld ae ‘home fly epne! sah erin suf hol nt san 9 ( Sid eerie mmo an) ep ee) fons pa ed oes crecem, [2 Conpesns bse Orne caaged odo ignoring toowes psec rae fa |o Toeclance oft (1) pt valve using and ein prof oe bse os ge |e Few ont sing ces of baz and aig Fn int 19 (03 anh and 08 an ecg Ble of he ete ave coe [2 mmo) escape hoe one tse coped |® Telenor oes) compere an compet Nis wotege4 Nz GOVERNOR Tr [Geng of ring [> Teri ah per paie: FUEL pocomane is ts trig conta kb) ‘et wane Ona bck om he compe sd potion, 1 Govnoroent 00100-1300 2000 mia"*cpm. (F298 1 Temp of datesona he emit sta sold ind deperatach send meron above ‘si img of esis an coe ok flowing ps andere tps hen. lo Te cannes beeen power andthe gare [2 Comper rod matteo [9 Pisa conal od demge [9 Gover spect won (9 fio or pg fit nt Ning ver aig a > ae [© Sc pp fe ent coo salad emi hao ge 516Procedures for Inspecting the Termioal Shaft Operat- ing Torgue Fig 526 Procedures for Inspecting the Presence or Absence of High-pressure Hydrate Oi Iflow into the Compen- ator Cae svmange: vcs. SENaat an e527 str @ Nz Governor AniaingPromane nein rr Detesen anne in ep Fig 528NZ Series Hydraulic Governor ‘Model NZ6U/NZ115 SERVICE MANUAL YANMAR CO.,LTD. Ist ition: aire, 1907 ‘sition: ly. 2000 re Eel: ly. 2005 Lsuedy: Precision felgnint vision ovr Syetr Orton Dvreen est over Pract Operate Devsion Yanmar Co, Lx Ese by: Yanmar Tecaia Service Co, LiIHI PERAAD —E Vii EXHAUST GAS TURBOCHARGER BX TYPE RH133 (Wersion: Y) BABI PSI TIT NOY 7" (@27O-bAVUYY) Bearing housing with foot (Semi-float bearing) ARR Instructions for operation and maintenance BIRPRETRARS Ishikawajima-Harima Heavy Industries Co., Ltd. TOKYO JAPAN RENaFSVA—AE:wamaem EAA RAL ‘lan theouioe ih os af 3 ne ata srs i sea at FeAUUAMENIS mI HRMEMOZE edt uot eine cae ly DRICAKERALT. SEU AU ASICHL pre nrg RaRERATEceeCeET. Ching snl Se doe ne ph mt RACHRMRBEEARAREROESIS hoy AOSUVRHERELTER, d AhusteseelcaKame Ase, 920 ET UNSUAMEC, WRN BEE A BERCEMRURT OR, RAMBIMARCEE 4 ———_ Caine ep on tin my oe gon ie ing aOR Fr ter Bow 60° i ei ex SEYADORZ=R- KE HFCHIED —ipbine etre AKERILET, COAROBRICKEMMENE The honing fit hed wp he mn BRE MICRAREMISRURMERCUET sche pig war ete oe ad, O° RNKDSCERREUTLEDUL EDR snleie web fhe ess ek AGE 9-ED ROARS EREUCOET, Sooke ray do aa eg URSA -MMRRL AMAIEEIRE vo nebny he eigen ROSHLEEHRT A RoI ORE —AhN) ea pt wer me ope Mt ie SUNORLYMSSEBSR MGIC EE se leaps eon te ein mopuer. ‘en eh han ese ing og vase fread aL eemcns, Avs see br sath SEAM I ALOT ROEM I7R een Aogimamens corey. Rama 12Gb eka Clating edd hee sy 199 ~ 3h RAMEE 19)~ 0 AMAL IEDM sane Ro cneRRL cCH2b, springy cae ssi tht42 Remoamen MADARA ss OTCENEHENT, CRMC RUMARAEON 2 LE amnL casas, sae armeME Tune 2a AmRALRA KREMER CKEED. SMT EAMEL TEED. SU DMS RM tee CMatO CHBCEE MLK. BAAR, KEIUTER OI Hremscumircerat, VT 2 Saammur sa peices, UPREAIBAL eto cca. AEONRDEKOONT. emmLcceat. Lax@ie-alz vn avinmeharLo en LCC, RR RURAL CIESL) ROKER KL ORENTECURATE.” PHLLORRELEN TCE. Bsn zune ocROMEL TEAL, TABOR eRMELTCHER BRL ORO RIT LER UCR ameLTEa, AWN TRUTAOTRERLT SLO AY AER RRLEMEL CCE, ssa AARMANOAKW CHT ERRLC nan ling ms be ee spe out of 8 Sp tape te inne (When ii esceti had opt ae IDA Tce sabe 8 "BCom a wan agp He he epee ahe3 Chek ein in hb tn, Bon a Vd hn cdl pe ae * Aaj we pores Te mt wr psa ibe le ater dng oe Gow shad Habe tela teushe\? eer aaeg tpl owe ahe VS+ samown727 45 Reb een apt RAQRIRIL, 92-5 PRABLOA, hole wyatt nmin Lp rang gE AME LEMMNERSCCEED. ecm emer dan 20a ce dy A a ») i SUMIECE ERY ARICA RELLY CCIEAD, )| the cae whee th dying re neon, esas 28. WORM AASBALE DSF OMNROER. DS Giamuncos —aceemencanena sure. | hart Ue seine sear i as teyrek,crming cores of Ger tte “ater haerng abe wn sarin the osama Areca nea Ri2FL SA ZIOIEMLCRE AE Aferth engin tps ve the dain wee VE BUDAUREIMAICEESIEL TCE, Lee endo that srl alr san be eared rm te oastonanome: 4. age parc ing RAAAMAMUERAR.AREDEEM tue she eapme penne (abt aw ma AEB CKEEAO vemeioe ater cig at pace ser DRUT HEA, 2~1 ARVALCRIL evn anichnk thing sar ner RED, URLAA ORR ENGMEIS Sie AEAIRORBERAGNETOT. ARNIS Ween we wots dot mca ening NaceeRaLRy, mobs rp “a sw cg pene ee ee BLE jt wich cs ego ay any°name TT REDBONE HELE P) OWNER CAME TTC CR, BIC EME THEM, Mee, SER BeeoTNC = eau, ARERMOLEMBUTED, FOREWORD ‘To-make full uilization of the IHT Exhaust Gas turbocharger hereinafter briefly alled turbocharger), it is important to comply with the procedures for operation and maintenance fs well as instructions contained in this instruction manual, Operate the turbocharger aftr reading through this instruction manualBaa LERTRU BMA ONT OMge CRRENSMAUTHORSe CH FED, wARH a wrameseee (GIDL) ee SRTaD, BREE 28% AMZ ReKmBeE ce BRAD. OCRRRGEMBVAbTACOWT RADOMLERM. 779-9 UA MH ERED YR AIAUARIA-V aE, Samer EO. 28RD RUE RIR. W)S ic THT OAR + OUR LICE HENS LIDS NRHA IT LAT (SA CMELEM ETA, KOWRM TA, BEMMH TH TORERAVDET. CAME MEN TSMR CHIC igo RAR DOwH OMMBRORMLRER SHADOW; QI MERRDAOMRE 77 eee a cos ICT OT, HeiRATRIC EERIE TRS be BIER ERT TP SRATM ERT BIL, PACORROM EA EAS RC (RUT REY. CAUTION (@)When ordering the pars, clearly indicate the following aymbola in your order sheet. ‘Type RE, Serial-No. ‘Aa stamped on the rating Specfiation J plateof turbocharger ‘Refer toFig.1) Part number fect] Speen ei Sana @Address your order and inquiry to. our ‘agencies “and service offices or engine builder's service stations 2.Exemptions of liability ‘in respect of acidenta during the guarantee period that are recognized as being clearly Sterbutable to IMs design oF manufacture, THI will make repairs free of charge, but ET vill assume no eeponsibilty even during the trusrantee period forthe following aeident, (Accidente due to the use contrary to the ‘nstrvctions contained in thie anal @Acsidents due toe neglect of periodic replacement of wearing parts (@ Accidente de to the use of parts other than THT genuine parts (Aosidante due te tho uso in oxcose of the ated capacity 8.Communication [Regarding the doubts about this instruction ‘manual, obscure points therein, special casos not stated therein or any disorder, et, please Contact’ the engine manufacturer or the ‘nearest THT business ofc. 4.Caution (0)Do not touch the turbocharger in operation, ‘because the turbocharger is ina high temperature and high-speed condition. ‘(2)Diemantle or remove the turbocharger after setting cold.ERRAUST GAS THI rossocrancer_| — type wees —P mee wuss “vey sweat ——P spo. c D ees 1 H emes ——> SERIALNo 7? Nmax: et ‘Tmax To THI TOKYO JAPAN anananeeen Maximum llowsble Speed ba and maximun allowance gas BaRSZaR temperature (ie, ena ig Rating plato12 REMIT SHRIER SUSN TORR WRAORS The inctructions here are designed to EFS LAC. BMRB LUE OMIM ensure your safety and to promote, safe ERBS PCOREHERDERBOLOT Ihandling of the tuebocharger and. its 7 operating material, cneoxetan. weMeReL Ths ‘Those safely instructions must be observed ES, SLCRMBSTHSLECE, OF rchpeeel ) Gtee ) BoesRan, ae Work on a turbocharger only in a stable LARKRELRRBOLEOD, WHE feeder a psineerpiotinny Rao cTCHED. Wear protective clothing (helmet, ear ARABI Ay b ETE SL PERE» yrotection, protective 's, protective FREE EMAL TSRED. Fictions protease) ‘Attach individual parte and large BxORBReCAMMLBREMRD M, Component modsles_caeflly to eitable MO te. 2ST ENT AIENE B Ainieg deviow, which are. in technialy REBERRL CERO, prefect condition and which pohest ‘Adequate load-bearing capacity ALURAROTICRIRD TCHR, ‘Do not stend under suspended loeds. BPCOMII ROMER EMM L. For overhead assembly work uso the stops BHEMAL TEED, land work platforms provided for thie purpose RRO BEBAEELTHMLAL TSE ‘Do not use machine parts as steps an If welding work isto be carried out above the turbocharger, the air iter must be ‘covered to provent damage tothe itor mat. REM LCM, WHO E77 NORE CHIC, MOE Lrewan. nnn 121 Safety when connecting Work only on those connections for which MUIR, RUREATS SRE, you are qualified. 122 BEB LOMRPORS 12.2 Safety when commissioning and uring operation FERBOARELTS Before starting to work make a visual inspection ofthe working area Bem KUZOMOmE, HRD Remove obstacles and any other cbjects aeTsean, \ying around from the work area mUgATIC, AAEIRICANRE L < MINAS Before, commissioning check the Wh, FEY TUT RaD, turbocharge for damage or leaks BeMORT, ReHEMS RIE ME Refrain from any activity which could Frye aien ahaha stil smpair safety at the turbochargerIRM LS i2bte< £1 BIC Lm, Inspect the turbocharger approx. every 12 RGU I ATI Ite ARLES hours or at least once a day for visible Ran, external damage and defects, GPR LOR EMBO RBSH, WEE Report immediately any damage or changes MSMMOL THR Bofore cleaning, protect the floor against: eueee eee errs scale a apa : Wear protective ching (land peta RMREMAL TSS (IER + OR . R-GHEM- OBC: RAM . protetion, fave protection, et petectin) A PAE BER MITT PERL TCE ‘Handle operation materials and detergents an ‘with wtmost caution. | hen handing solvent, protective BAERMT SE ARAR EMAL TCE clothing must be worn. Avoid contact with. COCCI DRTC ee en ton ) gudeeaccerse. Seat 227 yy 9RMOM, YL 7m EK — Water lah fom desing vel aauyamananee. Compre vashing124 ARBEVMUIORS 1.24 Safety when disassembling and sassombling HDRES AD TTD AMP RBRATICHS, Inform operating personnel accordingly LOH EMEMBACME ETRE, Sefore starting any speci or maintenance BORK, HERO FICAMANOLBOT ‘As precaution, place a receptacle for BERUTSESD. leaking oll under the turbocharger. BRMEANT Scat. O-FaBELE When disassembling, secure the rotor DESL OND RIEL TS Hal, against taming. Engure that absorbent materials toonk sp any spilled ide ailable CHAR MRERUMSKATESEDI. BORN EMME TEED, Bnrure that operation and process BAALONKERNT OMI, BET Taenale vase ‘drained, collected an RUAVKSIMMLT SEE, Alopowed of n'a cle end envonmently compatible manner. mC AAC NR Ensure that the prescribed, adjustment, FDA AREER, OREM OR reintenance and inepection Work scarred ab, cout atthe appropriate intervals BARRONS MARMBOMAI EST Obsorve instructions for replacement of cea, part znehotericity, mips heme Retighten screwed connections in Tan. accordance with the respective regulations WBMES HERNIA SRE T SE Do not touch the surface of locking devie, Bh, AEF SERS DET, ean ay Oo 12.5, Safety when shutting down DIS MEELBDAD IC. Lom BE basa hala ele erties Utsten, EARLE LCR SBIR TCE (Ceasthe turbocharger before mothballng. an, SHOLROREERTE, GAMER AL Wear protective clothing during Sean ‘othballing the turbocharger. PRASAD, MEZORORR ‘Keep the work are clean and free of il and EUTBENT SEED, operating materials SRBMERHL-T SEE. ‘Remove any obstacles laying arvund on the oor13 ARE AR: 13 Hazards and Hazard protection BIEMOMAL HEH CRANES. Hazards may arise during operation of, and work on, the turbocharger: BHRBAEOMMACESEO from the turbocharger and its socsesries teibIeE2ebO ftom the operating materials used RehRICRbEbo Ree from failure to observe safety instructions ALISA RIOR ER en os 1.3.1 | Mechanical influences Ako oe AN we AX warning! ROLE TRIREROEY. RELI TIswocaskqanases and injury 200 Ox UF SMaHRIET. Crushing, shearing, cutting, winding, HLORENS. iseHS, fragmentation, drawing in, knocking, amans. BaEKS. stabbing, rubbing, lose of liquids BAIL SHA BRS. ROS, under high pressure, under burnt, REMES, 45, BED COME, high temperature, sipping, tripping RRCLOKM, HS. CET. BR. falling. ao Causos BE RMOS. sharp edges, pointed parts DRSNS, WeeNS, BewENS rush, shear and winding areas E570 ae fragmentation of parts ) oe facture o rupture of parte due to overload elastic elements (6g. springs), liquids HEIR Kein). 2B KCK fand gases under pressure or ins FECA SMU, RIEIC A Soka vacuum OPTOMA slippery, olly work area, obstacles on fhe florsuk EMOFREMBLTS wor! EPROM ATH EMAL T THORS = tight and which do not comply with the" regulations on hazardous substance CPHHOHS CH NIbLSakER Emel Burning cigarettes or naked fame in the proximity of operation materials rome Protection moasuree (ePHHemomS Le, theme Tit” ation when bang lovewsn. poration and prowess material Protective clothing must be worn (oll — fem lilies ct ante) proof, solvent ~ proof and acid ~ proof SMM TSE lowes, impermeable. protective tlothing, and respiratory protection), ROCHE. BORARD TS ‘Avoid skin contact and inhalation LeWMUTSEEL, PRBORMELTS HED, tented. meron Posner ‘Observe the hazard indieations om the containers for operation and proce ‘materiale ACP MEMER LC SBME Immediately after use, seal the RRL CeO A> eH Inazardous substance container tight. EHUTSEED, Used operation materials must be Bem LAMM RERRICRENTEL

" (7008) 3: WAQOONI=WAT HAIN TH EPOCEORH HINER EDAD IE fea thes, Joa Fete Ame Cb 7H (OOD) ) ERA RET. RODE-PUP NTI RATE BUDE MOTI LION T ETE EAL DAC NEL A BL: aowet, 13 2, Construction and function 2.1 Construction of turbocharger ‘The RHI83 type turbocharger consists essentially of mixed flow turbine and a dial flow compressor assembled a5 a ele unt. (Turbine "The exhaust gas fom the diesel engine fows through the tusbine housing (4001) to the turbine whool and. provides the rotating torque to the turbine aha (1001), ‘The exhaust gas flows through the exhaust pipe tothe atmosphere, Seal ving 1008) and heat ehield (6008) are provided so that gas may act edversely affect ‘the besrings. @) Compressor ‘the comprossce whee! (2001) Std to the turbine shaft (100]) receives the rotating induces air through the silencer and delivers i othe lindere aber Seal plate(G001,6002) and seal xing(1010) is provided 0 that aad oi may nt lak ) Bearing AL_Thrustbearing(7002) ‘Since thruet free is constantly applied to ‘the turbine shaft (100), the thrust bearing (7002) is provided to prevent move of the that defo thrust foros 1B, Journal bearing A semioating type is employed, ‘A conventional floating bearing rotates, but ‘semi-flat bearing (7001) don’ rotate2.2 Pacts lst fie. Akt “Table.t Parts ie in Bi Designation st Parts No Quanity Toor |S=eSa=F [Turbine chat 1 wor [Aaa hno— [Trust collar 2 woos fre 2972U=2 intance piece 1 1006 fain Iseating buch 1 1008 faba 5 [Shaft end hexagon nut 1 109 P= >7 Gey ‘Sealing (Turbine sie) 1 row |2—uy>y Gy7ys8O [Seal sing (Conpressar side) 1 zor [ay FL a4 ye! (Compressor wheel 1 aor [S2FLyanaooy \Compreseor housing 1 sooz [32 7by veuPAie {Comprestor side clamp 8 aos [ARR Maxie lHexagon head bolt MSX16 8 aor [peng 7 [Turbine housing 1 4002 Peau [Turbine side clamp 8 goon [ett M10x20 liexagon head bolt M10x20 5 s001 [aru aynvyy [searing housing 1 so Ary Fy 7 [Snap ving 2 00a AAU Mexs0 lrexagon head bolt MGX20 6 soa |ittame 6 ISpring lock washer 6 6 soos feaNee [Heat shield i 5006 fou cso (Onng G90 1 sor lazvoyer ISpring pin i 5008 jour Oring 1 sos [Axno—nstary ‘Metal soal gasket 1 sora [799 Plug z so FL (2x7 yeH —|Soalplate (Compressor side) 1 soz PP V7L—b Gera {Sel plate (Turbine side) 1 yor fesza—RAv DT {Semi-float bearing 2 toon RAAT UT irhrust bearing 1 rooor [aaa Iitenear 1 ro0oe (RAAT 4 We [sir fltor 1 ro003 [sfc Mex<20 lexagon head bolt MSX20 4 ro00s |itzame 8 [Spring lock washer 8 4 “29 ibe 2 Structural drawing EZ. RH1 3 SRaisMER Fig.2, Structual Drawing for type of RHI33, THT TURBOCHARGER ENGINEERING DEPARTMENT [= >=" Reriazio | 158, ERE 3.1 einem RH BAUR, “72 BOREL. x DOMME RAT SE LARET. foe, ARH, DS ORRRR BORE keohenecmmray. S21 aE vo seRREI AMOREAMAD, ORBRAROR Bisoc Ray. A RUS TTR MEDIC BERLE. 32 a Dy Petey ca SUMNER ORE FEBR. KOMCRALTRED 321 eemw GRICE IRSET SRE, SBIEIRO RT DY RB ST SNARE LIL EE, Ltrs, Fo ORIN 17 WARROAD ar. TY" 002) RNS ARTERS AT CHBLT FSO, a 4. Maintenance 41 Cleaning When handling detergent, solvents, acide ‘and alkalis be iro to observe the respective safety” directions . on the manufacturer's label and in the operation manual, Obsorve also the instructions for the environmentally compatibly storage ‘and disposal ofthese substances. Warning! ‘Cleaning works should bo carried outdoors due to explosion hazards. If ‘this is not possible, ensure that there i ‘adequate ventilation. “Before beginning cleaning work in ‘confined spaces, extinguish naked flame Gneluding cigarettes) due to the danger of explosion. “Always wear protective clothing. 4.1.1 ‘Turbino shaft(1000, easing(3001,4001) and compressor wheel(200%) ©Dip the parts in warmed solvent to make epost so ®Remove the deposit with a plastic serapor ora hard:bristled brash, caro of damaging journal of turbine and atl ving way. AX caution! Do not use a wire bru 4.1.2 The other parts and filter of silencer 002) (Clean them in ight ol 413 Notice De not dip a silencer (6001) in salvent DDo not use a wir brush Trade an O-ring (6006) in for & new one ‘afer disassembling @Chean all parts by blowing air and wipe them by waste clothes afer washing Brpecally, clean the oil passage in the Dearing casing (6001) and the thrust Dearing (7002) by blowing air.42 ME 42.1 OTE 42.1.1 RRR MBE CAMA oa ER 18 FMI TY on Bor Wr RT Ht 1 4212 WIR at ona Mp17F (18mm,16.7 Nem) Wo (18mm,16.7 N-m Nove (Tem. N-m) HW (1mm 2.4 Nm) Hob (1omm 8-83 N-m) Tato PHN te 4.32 ams aioe aed 2 42 Toole 42.1 Necessary tools 4.2.1.1 Special tools (supplied by TH) Designation Qvantity ‘Turbine shaft locking toot m= 1 ‘Seal ving pliers 1 Snap ting pliers wns 42.12 General tools Open ended epanners (10/1817) ‘Torque wrench (13mm, 14.7 N-m) ‘Torque wrench (13me, 16.7 N-m) Torque wrench (17mm.45.1 N-m) ‘Torque wrench (I7mm.32.4N'm) Left-hand thas ‘Torque wrench (1Omm,8.89 N-m) Plastic hammer Serew driver 42.2 Measuring tole ‘Magnetic base Dial ewe43 mm A st BLOMBRLUABBRER SMALL 19 BAREKEY AMOCURY TER EER Ur hm ‘Table 3. Weigh of assomble Waa 1 ‘RAIS | Designation ae VIL yFRIIIT FAIA FD 7] WIS Comprossor housing (including Diffuser) [RPUDINO Ty Bearing housing | ms — BITI Turbine housing r #19 844 en 11 5 BORA OR EST A ee Wr OWRSLUAMERERS MSIE tte BUMS DAMON BY LVERERR Lean, EK BENCH HKO IE, TERETE an 441 esneemoRite RRR PADRUIIKB Ik C8 FORT AMIE STOR TOT. RHE AIST RED, 44.2 AFBEAICLOOOOROL ~ A561 SEFEO, Dx me 1110008), eta eI000H) ERAT. OMeBAT LODO ERAT. A 28! WITRPEMLOOODERDITR. sma ATE BLEDESERRUTFSD, 44.827" ohn 2 GOONOMAL — Hil 6.1 SITFEU. (DAME ba009), 17 L yA OLFRA H(9002) anny. Dor vyinhy F GooneBUre. ZN DT vob 9 GOOTYERIN THE. 227 bobo QONEWINVBLAILERL TREY. 44.4 227 W80N JOD ORIEL — 1B 61 SRS. Op-k >o-sansemaL ese FARRIS. De 7h 100 ERAT. LOK. MiB (lo0syi2ti" CTO, FHAAMICIL TS Rav, BUT Wo8ton joo eARMS. 37 ttn 9 (200 OHM ARR BENE. 05 9 LOOT FORE CHICA TS BRS URE. nis 29H RB 4 44 Disassembling the turbocherger ‘Refer to fig, Disassembling and ssembling. AX Warning! ‘Attach individual parts and large component modules carefully 19 suitable ‘are in. technically und which poseese ‘adequate loading-bearing eapacity Do not stand under suspended loads. 4.4.1 Branch position ‘Mark the turbocharger easing frst so that it ‘may be reassembled in the samo location from which it ia removed 44.2 Removing sllencer (10001) Refer to fig5-1 DRemove hexagon bolts (1000) and spring Tock washer (10008), @ Remove siloner (10007). AX caution! ‘Take cares no to damage the punched metal when dismantling silencer 4443 Removing compressor housing(300)) Refer to fig.51 Remove hexagon head bolts (3003) and compressor side clamp (3002). Remove compressor housing (S000), ZX Caution! ‘Take care not to damage the compressor blades (2001) when removing comprossor ‘housing (3001). 444 Pulling out comprescor wheel (2001) ‘Refer to g.6-1 install turbine shaft locking device to ga outlet Aang of turbine housing (400). ®Remove shat end hexagon nut (1008), This ‘otis lat hand threaded Pal out compressor whee! 2001). Whon it is dificult to pull out by hand, heat ‘compressor wheel@001) evenly below 100.4.4.5 F47 F-1(6001,6002)08UKL — 80 61 BAFED, DAAd' sG008). iztaMw (600) eB, BULL AA BN6005) 2 KER LITEM ELTMA, Hh bb G7 bot RUDD), 9 © yak(o02)) & 187 1000)¢—FEIC RAT. 44.6 252195.1002). X92H4 712Y (7002) 8UEL 9B 5.1 SHRFA0, Ov0-(1002) (7 HED EMU, Dy-bF b-HRAE MAA N008) 2 IML WE REL CHA, FOREN TI! (2000) HE r BAN <1002) HRED BRET 44.7 DE 297 WF GOONOMAL >) 7 ABsaeMFan, DAM NaooneRIT. Dye yaums A AI4002) ERAT. PE 97 9" (HOO EHAT. 2-0 207 (OOO RA LiKE. 7 SRS DTEI-E INDY AOODARERES AI can, A 8 AaB AAOOA) REMI EDC, HOE DE Lire SEUTREO, 448 92 aFaoooteRD = 4B 5.2 ORES, FE BY WOT" LOOM REET MODE Ie 0-900 SIVA IT Fan, J 4.4.9 EAH (6005) BUS L = 4 5.2 ORFS HEIR 00s) OR LASER ATR, 793 NATH MU TRL TRE, 25 44.5 Removing Refer tofig6-1 Remove heragon head bolts (6005) and spring loc washers (6004) @Using the removed 2 bolts, push up seal plate (compressor side (600%), turbine side (6002) with seaing bush (1000) pliae(6003,6002) 4.4.6 Removing thrust collar (1002) and thrust ‘bearing (1002) Refer to fg 5.1 Remove thrust eollar(1002) (eompreesor side), @Using the removed 2 bolts (6003) for eral late, push up thrust bearing (7002) @Romove thrust collar (1002) bearing sid) 44.7. Romoving turbine housing (4001) ‘Refer to Og 62 ‘DrRemove hexagon head bolts (400). @ Remove turbine side clamps (4002), @ Remove turbine housing (400) Whon removing is diiult, tap the turbine ‘housing 4001) by using plastic hammer, AX Caution! ‘The material of tho bolts (4004) for turbine housing (4001) is heat resisting steel, ‘therefore do not mix them with other bots, 448. Pall out turbine Refer to ig.6-2 ‘Do not remove seal ring burbine side) (1008) ‘xcept for inspection or replace. 4.4.9 Removing heat child (6005) “Rafer to 65.5.2 ‘When removing is dificult, tep heat child (6008) by using plastic hammer. safe (1001)4.4.10 7-829" (2009,101)0R4 ~ fmm 69 SMES 4.4.10.1 377 9 RI-HD9" (1010) 03884 L OBA LET Hoe 58-07 SAH (LOO EMIT. @aken» L006) % 5327 rH -b92>" LOI0) EDREAP DS HY THT OHAT e001) 4.4.10.2 9-8 E819" LOO) DMI D+F 20-7 1001, 59-E 7AL-W7" (1009) EDEERNDY AY HYORAT. A ze HSN EIT AYCRY BRET “PP EMICTRA, BONNY 51K DELTFaM, 4411 87) WORM ~ HELE BREED, Dus 97 9" (5002) BMH DIT HD" Tre. A zm 7 ses CERTI- TY WRESUTFED, (oon suit @es0-be OF POOERIT. a! BALIN TP RAMMED Utran. 26 44.10 Removing seal ring (1009,1010) Refer to ig 53 4.4.10.1 Removing seal ving (compressor side) aio) © Remove sealing bush (1006) from plate (compressor side)(600) @ Remove seal ving (compressor side) (1010) from sealing bush (1006) by wsing seal ring pliers which is supplied as a teal Sl 4410.2 Removing seal ring (turbine side) 1008) © Remove seal ing (turbine side)(1009) from turbine chaft (1001) by using seal sing pliers which is supplied as a too. AX caution! Whea removing seal ring (1009,1010) by suring seal ring pliers, hold seal ring by finger, not apply xcossve stress. 44.11 Disassombli Dearing Refer tofg5-4 DRRemove snap ving by using snap ring ‘lions, which ie inthe too AX caution! ‘Tako car to provent damage to semi-float bearing by using pliers. ® Remove semi-lot bearing. Caution 1 Handle these bearing parts with care to prevent damage4.5 tase 1B 5. SRR RMIESEMPEY, ATA MI IRL BHI TRB eRBLT RSH, 45.1 SDF Bom — He 64 SMFS. DH Ty nH ¥ (woo ict370-H6 7H" cTo0H BRATS, TOR, 20-471 WamMERL TRE, Ay 281 SIMA, MIRAE TDN" MAY DF OEY IWAICASR CL EMELT REM. x79" my 9" (GoOM}KcAIY7 92>" 00D). MBO RT WY THORENS. LN 81 THRisRT DY (GOOD EAEMAL. 7 Dy 97 WF GOONIEHEKICAD THB IEF crab. + Ata DN 6002S SWIPE PHP CTOONwUIE UTRA TF. 10 A497 MOOD) WRDUIAREI- LN BONS TEEREIC. 7 ARIE oN SRCAMSIMAL TREO, + AtaT WM Goosy EMMI SR. THERE L70-M THY" TOON RITE HD EE DIC BRLTFER, sHd97 POD) LARA 7" CoO ARI, IRIN OBE Le mL TREY. 45.2, Hy (009,101) 0m — AB 53 SHFEO, 45.2.1 3-8 0-H" (LOOMS DIF 32-9100) 129-€° 4039" .00B)e PMRW 7 HORNS. 49, Reassembling the turbocharger ‘Refer to fig, Disassembling and assembling Reassomble components after cleaning. Check and replace the damaged parts if necessary 4.5.1 Reascombling bearing Refer tofig5-4 © Tostall semi-loat beatings (7001) in beating housing (6001) Before inerting the semifloat bearings (7001), dip them in the Tbrcating oi AX Caution! ‘Turn the openings of semi-float boarings (700%) to inside and install them in bearing housing (6001). Mako sure the openings of ssemi-float bearings(7001) are wurely put in ‘the pins which are installed in bearing housing. ® Install snap ring (6002) in bearing housing (6001) hy using snap ring piers LX Caution! Make sure snap rings (6002) are firmly seated in bearing housing (5001) grooves + Install that the ssemifloat bearing (7001), + Tarn gap of turbine side snap ving (6002) to the let econ from turbine side and ‘compressor side snap ring (6002) to right Seen from compressor side. + Take care to provont damage to somifloat bearing (7001) by using p + Make sure the slight movement of somi- ‘oat bearings (7001) after snap rings are installed. 4.5.2, Reassembling seal ring (1009,1010) “Refer to fg.5-3 4.5.2.1 Reassombling turbine side (009) ® Insta seal ring (1009) in turbine shaft roove (100%) by using seal rng pliers4.5.2.2 377 WABL-HD" LOLO)OMAN wIY 00H L377" HFBL-H9" COLE BREED MNT HYCRAT D. AN em 83-0Y (009,1010)87 HY CHIT BM UTHRTLA TEED, 4.5.8 ERRG00H) DML — 1B 52 SEF De Py" no’ 27 Gory HEARN 6005) ER, ape. 45.4 7 4Q00n ots = fila 6:2 BITRE. Ope yay oop amtBREN HSE E EMBLT. FE 7o-9UODVE PP 109" ¥ GOODKS-€ 0h SHAT S. AN 28 “PE wIqoONoy y-HaBic mM EBA CS MAAT RED, “Poe a IY" (100A E LS ILT WALTRE, “Joe DILDO EMA BA ANIEN TH 199 ¥ GOODAICRRORIBEMIEL TFS. “FE AY-AIY" (1009) LO RSIMATS RIC F100) ARTA SALT ERRDELET, LOMICHI-E PANDY” C00} HHEI-E IMO HOLS HET HALTFSD, 28 452.2 Reassombling comprestor side seal ring (1010) © Install seal ring (1010) in sealing bush groove (1008) by using seal ring pliers, AX caution! Whon installing seal ring (1009,1010) by tating pliers, always old seal ring by finger. 45.8 Reassombling heat shield (5005) oer to fg 5:2 © Install heat shield (6005) to. bearing housing (6003). 45.4 Reassembling turbino shaft (1001) “Refer to fig 5-2 © Afr installing seal ring (1009) to turbine ‘aft (1001), install turbine shaft (1001) to bearing hosing (6001 fom turbine side A Caution! + Bofore installing turbine shaft (100%), apply lubricating oil on the sha + Turn gap of ceal ving (1009) to upwards. Before installing turbine shaft (1001), ‘ascertain that there ie no foreign Body in the bearing housing (6001), + For aafety inserting of turbine side aeal ring (1009), vertical installing of turbine shaft (1001) is recommended. At inserting of turbine shaft (1001), place the center of it to the conter of turbine shaft (1001),45.5 E07 9" Moonee 4 62 SMFE, OSM AMIR A eR Dee DETT-E INN (400) 727 193" 9" GOON MAE. Ie OUR A 4002) KEEP $4008) SIRNA HINNE 4512049 (Nom) APE DAO) IKE NEAIENLALE MATL TREY, DIMA RAEN. CF eM_L TH < 45.6 19RH19-(1002), 39Ah 79" (7002) 8 5 = 18 1 SAFER, DrpH4>- 100 (HEAD Pe’ 29-9(1009) BATS. @rabe oy coos) PHy 10329 (GOOD BFE 1600 OEEMICe ETRY S75 AAT GOUDICIAS Sm Ube EIA Lar PIN 05"29" GOONOAAE SbecMsns, @uAby-(loo2) 37 vos) #9-€ 20-9000) IMATE. 45.7 WF 1-Ke001,000) 08831 ~ AB 51 BHIFEL, Dm» 1006 £327" Vo 940 FBI YF (OONEMATS. DAN ea 7D C006 KEIRA STURT bys FACS, LMEBEL IMAL TREN @o $29" one) 7929" nay 29" GOOD EI: Av. A xm 0 12" oveyihta Ente sRibicts Siw kD cRErED. (Bmve7» 1006) aia 7-87" y-K001 6002) EN IUP WY DY GOODIAAT. @isiases 6002), WAai’ $6009) RATS. HTH B83 Nem) CF 4.5.5 Reassombling turbine housing (4001) Refer tfig.5-2 © Install turbine housing (4001) to bearing housing (600%) by aligning the mark. @ Install turbine side. clamps (4002) and hexagon head bolts 4004). Tighten bats by 4512049 (Nem), AX Caution! Apply seiaure prevent compound on bolts ® Install turbine shat locking device. 4.5.6 Reassembling thrust collar (1002) and ‘thrust bearing (7002) “Refer tofig5-1 © Insert thrust collar (1002)(bearing cide) to turbine shaft (1001). ® Set thrust bearing (7002) into the knock pin (5007) ofkearing housing (6001) Apply ting oon the thrust bering (7002. thrust bearing (7002) to bearing housing (6001) with aligning Iubeieating bale @ Insert thrust collar (1002) compressor side) to turbine shaf (1001), 4.5.7 Reascombling seal plato (6001,6002) ‘Refer to fig5-1 © Insert sealing bush (1000) in (L002) compressor ede) AX Caution! al plate ® Insort “O° ring(6006) in the groove of bearing housing(6001) AX Caution! Do not tobe twisted "0" ring (5008). @® ‘taste seal plate (6001,8002) inserted ‘sealing bush (1006) to bearing housing (6001). @ Install spring lock washers (6004) and Ihexagon head bolts (6003). Tighten bolts by 8.88 (Nm), 2945.8 7 AX 3200) HL HH 51 SEED. N79 300 E9-e Ta. Deis 2008) e135. Abt h008)zE WCPO, RENAME TS ESO, (918 92.4 Om) T Ay 2 227" 2 52001) REIABARI-L 20-4200) 08 ih, EAMOBTEMBLTRED, (G523KESMFED. ) 31009 4.5.9.7 Voy OMLAE(SOOD, — M61 SHFEO, DAMNED ABT Deeb ET IT HAMOy 27 (OO) E* TF" My 2 GOODKMAL, DmaBEUAME HHe00a) ERENT. HIE HE 167 Wm) CF. 4.5.10 Wee M L000) Oka — HE 1 SARE, Dwar LON EF VHA» oor Kako. @AME 10008). KetaMs@ LO00g} EMA B, BAMA 147 Oem) CF 0 4.5.8 Reassembling compressor wheel (2001) ‘Refer tofig5-1 © Inoort compressor whee! (2001) to turbine shaft (100). ® Intall shaft end hexagon nut (1008) to turbine chaft (1001), This nut i left-hand ‘threaded. Tighten bolt by 324 (N-m) AX caution! After installing compressor wheel (2001), check clearances in axial and radial ‘irection, Refer to tem 3.5.2.8) 4.5.9 Reassembling compressor housing (8001) “Refer tog 5-1 © nstall comprestor housing (8001) to boaring housing (6001) by aligning the mark @ Install washer and hexagon head bolts (2009), Tighten bots by 16.708) 4.5.10 Reassembling silencer (10001) oferta fig 5-1 Dinotall aiden (10001) w comprector housing (8000, @Install hexagoa head bolts (10003) and spring lock washer (10004). Tighten bolt by 147 Ove),BARE 51 FREER RGRIAM LETS, cORRERRICRM TET. AMO ahAAASNEeA. S DESMAN BO ET LY MO eH. OF MIRREN CLeReL LOSK, HORMEE TEOWRE ELT HLMREHFS TREY, 5.1 ME aI, BL Faasaclannemakaneey Ganenuse row DBRT ISI Naz uy Fo bo mun Bicmi FMR BEL MLAB,Pitot REERMLLOT. Sit eomamucnemaits ReRweRruesn meemORO Coat, Boo vo TemRORES sure rie wp wet esr tee men sing sone fa 1 see etna Sian Ze ws aso ymmemsier. wm Ew iit eo se MBL Ftresom aio TmeMTIR ERG Gimmes ceo9ay vem 1. TaRLEAR MER RRERL CES tae sunacemra Eiattemonner Smmase (ferme esau fuga accra ft cn veeeeeege orem ons Sadeeee a oeae eee eae ee ARO I> eae 7sHM FLERE TMC COGMMECENETD CELCEED ISA RA A as ABLE HOMBCRAR LLAMA SROMmeRML cosa, sammemin aencrse71 E79 DT ERBLCRAN. + amRReM(cs eva somEKe Oasis imo aiGORASRE aL eee, pa mmemRe! Rnshamanewmomnanas BERL TOES