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Bienvenido: r180axg
Producto: GAS ENGINE Modelo: G399 GAS ENGINE 49C01524 Configuracin: G399 ENGINE 49C00261-UP
Instruccin Especial
Instructions for the Service Replacement of the Turbochargers{1052}
Nmero de medio -SEHS9597-09 Fecha de publicacin -29/04/2010 Fecha de actualizacin -29/04/2010
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Introduction
This special instruction provides the instructions for the installation of the turbocharger. Turbochargers are sensitive to contamination. Failure to follow any of the procedures may result in damage, a malfunction, or possible engine failure. The following items have been made available to help reduce premature Turbocharger failure due to contamination. A magnetic cover SELD0271 has been placed over the oil inlet on the turbocharger. A quick reference Critical Requirements, REHS3033 has been attached to all turbochargers. An instruction manual for turbocharger failures has also been published in order to assist in diagnosing turbocharger failures. The document is Special Instruction, SEBF9085, "Failure Modes of Turbochargers".
NOTICE
The correct procedures and tooling specifications must always be used. Failure to follow any of the procedures may result in damage, malfunction, or possible engine failure.
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General
1. Clean the area around the turbocharger in order to remove potential contaminants. 2. Examine the turbocharger for potential causes of failure. a. If there is any damage to the turbine wheel, examine the exhaust system and the exhaust manifold to ensure that no foreign material remains. b. If there is any damage to the compressor wheel, examine the air cleaner, the aftercooler, and the ducting to ensure that no foreign material remains. c. If there is any sign of oil on the compressor side, inspect the accumulator/oil separator and the aftercooler.
NOTICE
Oil that is left in the Air-To-Air Aftercooler can result in engine overspeed.
3. Work in an enclosed area or use tarps to minimize the entrance of airborne debris. Leave the SELD0271 magnetic cover in place over the oil inlet on the turbocharger. The cover will help prevent contamination during installation. 4. The bolts in the turbochargers may be intentionally left loose in order to facilitate the installation. Extra bolts may be required. Proceed to the Installation and Prelubing of the Turbocharger section if the following items are complete. The turbocharger compressor housing and the turbine housing are aligned. The bolts should be tight. All of the locking tabs should be bent upward.
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4. Tighten at least two of the bolts or the V-band clamp in order to lock the center housing to the turbine housing. 5. Rotate the compressor housing until the housing lines up with the intake manifold or the aftercooler outlet line. Tighten at least two of the bolts or the V-band clamp in order to lock the housing in place. 6. Complete the following before you remove the turbocharger from the engine. a. Tighten all of the bolts or the nuts on the V-band clamp. b. Tighten the bolts alternately in order to prevent any cocking of the housings. c. Tighten the bolts to the recommended torque. d. When the V-band clamps are correctly positioned, tighten the nuts of the V-band clamp to the specified torque. Gently tap around the clamps. Tighten the clamps again to the specified torque. ReferenceRefer to the Specification, "Turbochargers", and the Operation and Maintenance Manual for torque values and additional information.
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7. Perform the following procedures to the oil bypass valve. First, remove the oil bypass valve. Then, inspect and clean the oil bypass valve. Finally, reinstall the oil bypass valve. Note: If debris is found on the oil bypass valve, the oil pan must be removed and any debris must be cleaned from the oil pan. If the remaining debris is not removed, the oil bypass valve will be recontaminated upon start-up. 8. CHANGE THE ENGINE OIL AND THE FILTER(S). 9. Check the oil level in the engine crankcase. ReferenceRefer to the Specification, "Turbochargers", and the Operation and Maintenance Manual for torque values and additional information.
Additional Information
ReferenceRefer to Special Instruction, SEBF9085, "Turbocharger Failure Modes" for additional information on turbocharger failures.
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