M.R.

14002

MODERNIZATION RECOMMENDATION

Extended Light Load Turbocharger

TABLE OF CONTENTS

PURPOSE ......................................................................................................... 2
BACKGROUND………………………………………………………….......2
APPLICATION ................................................................................................ 2
REFERENCES ................................................................................................. 2
DISCUSSION ................................................................................................... 2
MATERIAL REQUIRED ................................................................................. 5
PROCEDURE ................................................................................................... 9
PURPOSE

To offer a Light Load Specific Turbocharger and associated piping in the event that
light load operation cannot be avoided. The application of this equipment will
increase the turbocharger gear train loading capacity due to extended light engine
load operation.

APPLICATION

20 cylinder Model 710 Turbocharged Engines in Generator Service or Synchronous

Operation

REFERENCES

SA 10-026 Light Load Inspection

Applicable Engine Maintenance Manual

DISCUSSION

EMD engines, like other internal combustion engines, operate most efficiently when
producing the power for which they were designed. Under normal operating
conditions load can vary based on environmental conditions and equipment demands.
Power Plant Load Management systems can and should be designed to minimize the
number of engines on line at any time in order to maximize load, optimize fuel
economy, and minimize any issues related to light load. The rapid response of the
EMD two-cycle engine allows for fewer engines to be on line at any time to meet
transient power requirements.

Under typical operating conditions high driving torque can be transmitted through the
turbo gear train for a short time. As the engine load is applied, the power needed to
mechanically drive the turbo is proportionally decreased on the gear train by the
turbine. The turbine uses exhaust gas energy to decrease the gear train load. At
approximately 70% of full rated load, the exhaust energy is sufficient to drive the
turbocharger rotating assembly without any gear train assist. At this operating
condition, the overrunning clutch allows the turbo to speed up and run independent of
the gear train: the gears continue to turn at their corresponding speed ratio to engine
RPM without transmitting torque.

If engines are operated for extended periods at full speed with light loads, turbo gear
train wear is accelerated. At loads below 70% wear rates gradually increase, however
operating the engines during construction where loads could easily be below 10%
load for sustained periods of time the wear rates could reduce the life of the drive
gears to 3000 hours of operation with a standard turbocharger.

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 EMD engines operated at full speed and less than 20% load can experience oil
accumulation in the exhaust system. Engines equipped with Low Lube Oil power
assemblies or engines that carry a US EPA Tier 2 certification will experience less
accumulation. The exhaust system can be cleaned out by operating the engines at
70% load or more for at least 30 minutes. This should be performed after 8 hours of
idling or 100 hours of continuous operation at synchronous speed with less than 20%
load.

This Modernization Recommendation is being issued to mitigate the effects of

extended light load operation on the subject applications. The design goal was to
improve turbocharger gear train life such that it will operate in constant speed
applications, which includes loads below 30%, for a minimum of 30,000 hours
(typical overhaul recommendation). The upgrade implements changes to the
turbocharger and support systems that result in a reduction in turbocharger gear
loading and includes new gears capable of higher load capacities.

The turbocharger assemblies that will be applied are equipped with internal nozzles
that are custom designed to direct oil flow [supplied via external piping] onto critical
areas of the gear train.

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 The external oil supply will be sourced from the main lube oil system via external
piping applied to the engine as part of this upgrade. An electronic valve assembly will
be controlled via PLC to start / stop oil delivery to the gear train as required. The PLC
opens the turbo oil valve only if engine speed equals 900 RPM and EngineR is below
50%. This functionality is separate code added to the PLC and has no interaction
with local or remote control capabilities of the engine control panel. At higher
engine loads the external oiling system will be deactivated.

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MATERIAL REQUIRED

Turbocharger:

Engine Current Gear Light Light Current Light Load

Model New Ratio Load Load Utex Utex Turbo
Application Turbo Turbo Gear Turbo Asm Asm.
Asm. Asm. Ratio
L20- 40144401 17.1:1 40224469 16.8:1 40144562 TBD
710G7CT2
L20-710G7B 40078759 17.1:1 40224470 16.8:1 40108872 TBD
R20-710G7B 40082869 17.1:1 40224471 16.8:1 40108875 TBD

Clutch Drive:

Current Light Engine Description Quantity

Clutch Load Clutch Required
40105390 40232872 Clutch Dr. Assembly-LH 1
40149187 40232929 Clutch Dr. Assembly-RH 1

Note:

Only one of the following four oil spray piping application(s) needs to be selected
based upon your engine model.

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Oil Spray Piping Apl, 40226134 for ME20G9B Engine

Qnty.
Item No. Name of Part Part No. Note
Req”d
1 TUBE ASM 40225595 1
2 TUBE ASM 40225596 1
3 TUBE ASM 40225527 1
4 TUBE ASM 40225528 1
5 TUBE ASM 40225500 1
6 BRACKET ASM 40168064 1
7 BRACKET ASM 40165535 1
8 BRACKET ASM 40165532 2
9 BRACKET ASM 40165530 1
10 BRACKET ASM 40165545 1
11 CLAMP ASM 40165540 1
12 MANIFOLD-REDUCER 40163443 1
13 SOLENOID VALVE 40168059 1
14 CONN-3/8T-3/8PT 8040313 2
15 CONN-5/8T-3/8PT 8040321 2
16 CONN-5/8T-1/2FPT 144461 2
17 NIPPLE-1/2-3 8142967 2
18 NIPPLE-3/8-3-1/2 120128 1
19 UNION-5/8 TUBE 119467 1
20 BUSHING-3/4-3/8PT 189061 1
21 ELBOW 90 DEGREE 3/8 119097 1
22 BOLT-3/8-16 HEX 180124 8
23 BOLT-3/8-16 HEX 180132 2
24 BOLT-1/2-20 HEX 181435 4
25 BOLT-3/8-24 181379 2
26 NUT-3/8-16 HEX 102635 1
27 NUT-3/8-16 SLFLKG 8035146 8
28 NUT-3/8-24 SLFLKG 8032717 2
29 WASHER-3/8 FLAT 103341 1
30 WASHER-3/8 FLAT 120394 16
31 WASHER-3/8 AIRCRAFT 6101225 4
32 WASHER-1/2 AIRCRAFT 6101229 4

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Oil Spray Piping Apl, 40226596 for ME20G7B Engine

Qnty.
Item No. Name of Part Part No. Note
Req”d
1 TUBE ASM 40225595 1
2 TUBE ASM 40225596 1
3 TUBE ASM 40225527 1
4 TUBE ASM 40225528 1
5 TUBE ASM 40225500 1
6 BRACKET ASM 40168064 1
7 BRACKET ASM 40165535 1
8 BRACKET ASM 40165532 2
9 BRACKET ASM 40165530 1
10 BRACKET ASM 40165545 1
11 CLAMP ASM 40165540 1
12 MANIFOLD-REDUCER 40163443 1
13 SOLENOID VALVE 40168059 1
14 CONN-3/8T-3/8PT 8040313 2
15 CONN-5/8T-3/8PT 8040321 2
16 CONN-5/8T-1/2FPT 144461 2
17 NIPPLE-1/2-3 8142967 2
18 NIPPLE-3/8-3-1/2 120128 1
19 UNION-5/8 TUBE 119467 1
20 BUSHING-3/4-3/8PT 189061 1
21 ELBOW 90 DEGREE 3/8 119097 1
22 BOLT-3/8-16 HEX 180124 8
23 BOLT-3/8-16 HEX 180132 2
24 BOLT-1/2-20 HEX 181435 4
25 BOLT-3/8-24 181379 2
26 NUT-3/8-16 HEX 102635 1
27 NUT-3/8-16 SLFLKG 8035146 8
28 NUT-3/8-24 SLFLKG 8032717 2
29 WASHER-3/8 FLAT 103341 1
30 WASHER-3/8 FLAT 120394 16
31 WASHER-3/8 AIRCRAFT 6101225 4
32 WASHER-1/2 AIRCRAFT 6101229 4

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Oil Spray Piping Apl, 40225285 for ME20G7C-T2 Engine

Qnty.
Item No. Name of Part Part No. Note
Req”d
1 TUBE ASM 40225595 1
2 TUBE ASM 40225596 1
3 TUBE ASM 40225527 1
4 TUBE ASM 40225528 1
5 TUBE ASM 40225500 1
6 BRACKET ASM 40168064 1
7 BRACKET ASM 40197581 1
8 BRACKET ASM 40165532 2
9 BRACKET ASM 40165530 1
10 BRACKET ASM 40165545 1
11 CLAMP ASM 40165540 1
12 MANIFOLD-REDUCER 40163443 1
13 SOLENOID VALVE 40168059 1
14 CONN-3/8T-3/8PT 8040313 2
15 CONN-5/8T-3/8PT 8040321 2
16 CONN-5/8T-1/2FPT 144461 2
17 NIPPLE-1/2-3 8142967 2
18 NIPPLE-3/8-3-1/2 120128 1
19 UNION-5/8 TUBE 119467 1
20 TEE-3/8PT 120280 1
21 BUSHING-3/4-3/8PT 189061 1
22 BUSHING-3/8-1/4PT 144043 1
23 BOLT-3/8-16 HEX 180124 8
24 BOLT-3/8-16 HEX 180132 2
25 BOLT-1/2-20 HEX 181435 4
26 NUT-3/8-16 HEX 102635 1
27 NUT-3/8-16 SLFLKG 8035146 8
28 WASHER-3/8 FLAT 103341 1
29 WASHER-3/8 FLAT 120394 16
30 WASHER-3/8 AIRCRAFT 6101225 2
31 WASHER-1/2 AIRCRAFT 6101229 4

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Oil Spray Piping Apl, 40226005 for ME20G9C-T2 Engine

Qnty.
Item No. Name of Part Part No. Note
Req”d
1 TUBE ASM 40225595 1
2 TUBE ASM 40225596 1
3 TUBE ASM 40225527 1
4 TUBE ASM 40225528 1
5 TUBE ASM 40225500 1
6 BRACKET ASM 40168064 1
7 BRACKET ASM 40197581 1
8 BRACKET ASM 40165532 2
9 BRACKET ASM 40165530 1
10 BRACKET ASM 40165545 1
11 CLAMP ASM 40165540 1
12 MANIFOLD-REDUCER 40163443 1
13 SOLENOID VALVE 40168059 1
14 CONN-3/8T-3/8PT 8040313 2
15 CONN-5/8T-3/8PT 8040321 2
16 CONN-5/8T-1/2FPT 144461 2
17 NIPPLE-1/2-3 8142967 2
18 NIPPLE-3/8-3-1/2 120128 1
19 UNION-5/8 TUBE 119467 1
20 TEE-3/8PT 120280 1
21 BUSHING-3/4-3/8PT 189061 1
22 BUSHING-3/8-1/4PT 144043 1
23 BOLT-3/8-16 HEX 180124 8
24 BOLT-3/8-16 HEX 180132 2
25 BOLT-1/2-20 HEX 181435 4
26 NUT-3/8-16 HEX 102635 1
27 NUT-3/8-16 SLFLKG 8035146 8
28 WASHER-3/8 FLAT 103341 1
29 WASHER-3/8 FLAT 120394 16
30 WASHER-3/8 AIRCRAFT 6101225 2
31 WASHER-1/2 AIRCRAFT 6101229 4

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PROCEDURES

Turbocharger / Clutch Drive Installation Procedure

1. Remove existing turbocharger and clutch drive assembly per instructions in

“Engine Maintenance Manual”, i.e. EMM.

2. Install new or utex turbocharger and new or utex clutch drive assemblies as
identified in material requirements section of this service release per
instructions in “Engine Maintenance Manual”, i.e. EMM.

Oil Spray Piping Installation Procedure

It should be mentioned that the procedure for oil spray piping application of all four
engine models are very similar. There is only a minor difference at front end of the
engine between EUI and MUI engines (see Figure 3). Therefore, the following
procedure only describes one engine model application, ME20G9B and is a MUI
engine.
1. Refer to drawing, 40226134, and Figure 1 for the oil spray piping application
being installed to the LB of 20-710G9B engine.
2. See Figure 2 for drilling the two mounting holes on each of the four gussets as
shown in Figure 1. It should be noted in Figure 2 that there is minor differences
in hole locations between the gusset drilled for valve supporting bracket and the
rest three gussets which are used to support the oil piping.
3. Retrieve the provided materials, mount and tighten the three mounting brackets
to gussets.
4. Refer to application drawing, 40226134, and Figures 3 and 4, and retrieve the
provided materials and Install mounting brackets, clamp, and manifold reducer
to the front end and the rear end of engine,
5. Install the solenoid valve,40168059 to the mounting bracket as shown in Figure
5.
6. See Figures 1, 3, and 4, retrieve the provided materials, install and tighten the
five tube assemblies to engine, It should be pointed out that the rear end tube
assembly, 40225528, must be installed at the time of turbo installation while
both turbo and aftercooler ducts are being removed.
7. Route the two control wires of the 24VDC solenoid valve (see Figure 5) to PLC
box of the engine.
8. Run engine and check for oil leak at all joints of the piping assembly.

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 Figure 1 – Turbo Gears Oil Spray Piping Application

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 Figure 2 - Drill Locations on Gussets

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 Figure 3 - Piping Connection at Engine Front End

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 Figure 4 - Piping Connection at Engine Rear End

24 VDC
Solenoid
Valve Wires

Figure 5 - Solenoid Valve Installation and Control Wires Routing

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 External oil control valve - control system specification:

PLC control logic and wiring is to be completed by EMD distributors.

Engine rpm = 900

(1) For MUI Engines (for applications 40226134 & 40226596)

1. When rack setting is 1.55 or greater, open oil valve (controlled operation).

2. When rack setting is shorter than 1.55, close oil valve (normal operation).

3. Depending on actual duty cycle power, it may be necessary to shift the rack
setting slightly or create a timed dead band to prevent over cycling of the
valve

(2) For EUI engines (for applications 40225285 & 40226005)

1. When Engine R is 0.50 or less, open oil valve (controlled operation).

2. When Engine R is greater than 0.50, close oil valve (normal operation).

3. Depending on actual duty cycle power, it may be necessary to shift the

Engine R set point slightly or create a timed dead band to prevent over
cycling of the valve.

Lower engine rpm < 900

No control of external oil control valve is required. Valve is in closed position.

Reference Drawings

1. Oil Spray Piping Apl, 40226134 for ME20G9B

2. Oil Spray Piping Apl, 40226596 for ME20G7B
3. Oil Spray Piping Apl, 40226005 for ME20G9C-T2
4. Oil Spray Piping Apl, 40225285 for ME20G7C-T2
,
,
,

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 CAUTION
Please refer to the EMD Safety Precautions section in the applicable Engine Service
Manual whenever routine service or maintenance work is to be preformed.

All shop safety rules and practices must be followed at all times during this procedure.

(D-L)

Electro-Motive Diesel, Inc.

La Grange, Illinois 60525 USA
Telephone: 708-387-6000
Website: www.EMDiesels.com

©2012
Electro-Motive Diesel, Inc. All rights reserved. Neither this document,
nor any part thereof, may be reprinted without the expressed written
consent of Electro-Motive Diesel, Inc. Contact EMD Customer
Publications Office.

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