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SERIES 60 TURBOCHARGER SERIES 60 GAS ENGINES (GENSET)

The turbocharger is designed to increase the overall power and efficiency of the engine. Power to drive the turbocharger is extracted from the energy in the engine exhaust gas. ‪

A turbocharger can be broken down into 3 basic pieces; a compressor cover, a center housing rotating assembly (CHRA), and a turbine housing. ‪

The compressor cover is an aluminum alloy casting that encloses the compressor wheel and provides a V-band connection for the compressor outlet, and a hose connection for the compressor inlet. The compressor cover is secured to the compressor side of the CHRA. ‪

The CHRA contains a turbine wheel and shaft assembly, piston ring(s), thrust spacer, compressor wheel, and wheel retaining nut. This rotating assembly is supported on two pressure-lubricated bearings that are retained in the center housing by snap rings. Internal oil passages are drilled in the center housing to provide lubrication to the turbine wheel shaft bearings, thrust washer, thrust collar, and thrust spacer. ‪

The turbine housing is a heat-resistant steel alloy casting that encloses the turbine wheel and provides a flanged engine exhaust gas inlet and an axially located turbocharger exhaust gas outlet. The turbine housing is secured to the turbine end of the center housing. ‪

All Series 60G, 60 Hz Genset engines use a model K33 turbocharger, manufactured by 3K turbosystems. See Figure 27854 . ‪

1. Compressor Inlet ‪

4. Turbine Housing ‪

2. Compressor Housing ‪

5. V-Band Clamp ‪

3. Turbine Housing Bolt ‪

6. Compressor Outlet Adapter ‪

K33 Turbocharger Assembly (1996 Model)

This turbocharger is similar in appearance to the diesel turbochargers. ‪

For the 1996 model year, the compressor cover has an adaptor cone on the compressor outlets, attached with a V-clamp. This compressor cover is attached to the CHRA with a bolted joint. For the 1997 model, a new compressor cover with the correct compressor outlet dimensions will be introduced, eliminating the adapter cone. The new cover will be secured to the CHRA with a V-band clamp. These compressor covers will not be interchangeable. See Figure 27875 . ‪

1. Compressor Inlet ‪

4. Turbine Housing ‪

2. Compressor Housing ‪

5. Compressor Outlet ‪

3. Turbine Housing Bolt ‪

K33 Turbocharger Assembly (1997 and later Model)

The turbocharger is mounted on the exhaust outlet flange of the engine exhaust manifold. After the engine is started, the exhaust gases flow from the engine and through the turbine housing causing the turbine wheel and shaft to rotate. See Figure 27917 . ‪

Schematic Air Flow Diagram (Series 60G Engine, low pressure fuel system)

The gases are discharged into the exhaust system after passing through the turbine housing. ‪

The compressor wheel, in the compressor housing, is mounted on the opposite end of the turbine wheel shaft and rotates with the turbine wheel. The compressor wheel draws in clean gas and air, compresses it, and delivers high pressure air and gas through the throttle and intake manifold to the engine cylinders. ‪

Oil for lubricating the turbocharger is supplied under pressure through an external oil line extending from the oil filter adaptor to the top of the center housing. See Figure 27876 . ‪

1. Coupling Hose Clamp ‪

4. Flexible Coupling ‪

2. Charge Air Cooler Outlet Duct ‪

5. Turbocharger ‪

3. Charge Air Cooler ‪

6. Charge Air Cooler Inlet Duct ‪

7. V-Band Clamp ‪

Turbocharger Oil Lines Series 60 Gas Engine (Low Pressure System)

From the oil inlet in the center housing, the oil flows through the drilled oil passages in the housing to the shaft bearings, thrust ring, thrust bearing, and backplate or thrust plate. See Figure 20419 . ‪

1. Compressor Wheel ‪

6. Shaft ‪

2. Thrust Bearing ‪

7. Turbine Wheel ‪

3. Backplate ‪

8. Shaft Bearings ‪

4. Oil Inlet ‪

9. Oil Outlet ‪

5. Center Housing ‪

Turbocharger Oil Flow Diagram (Series 60G Engine)

The oil returns by gravity to the engine oil pan through an external oil line extending from the bottom of the turbocharger center housing to the cylinder block. ‪

Listed in Table are the diagnostic codes. ‪

Parameter Identification Character (PID): A PID is a single byte character used in J 1587 messages to identify the data byte(s) that follow. PIDs in the range 0-127 identify single byte data, 128-191 identify double byte data, and 192-253 identify data of varying length. ‪

Failure Mode Identifier (FMI): The FMI describes the type of failure detected in the subsystem and identified by the PID. The FMI and the PID combine to form a given diagnostic code defined inJ 1587 within PID 194. ‪

DDR Description

Voltage

PID

FMI

Information

AIR INLET PRESSURE ‪

HIGH ‪

106 ‪

0 ‪

Indicates that the MAP has detected that engine intake manifold pressure has exceeded the recommended operating range. ‪

AIR INLET PRESSURE ‪

HIGH ‪

106 ‪

3 ‪

Indicates that the MAP input to the ECM has exceeded 95% (normally >4.75 volts) of the sensor supply voltage. This diagnostic condition is typically detected when there is an open sensor return circuit or the sensor signal circuit is shorted to the sensor +5 volt supply. ‪

AIR INLET PRESSURE ‪

LOW ‪

106 ‪

4 ‪

Indicated that the MAP input to the ECM has dropped below 5% (normally, 0.25 volts) of the sensor supply voltage. This diagnostic condition is typically detected when there is:- An open sensor signal circuit- An open sensor signal circuit opens sensor +5 volt supply circuit- The sensor signal is shorted to the sensor return circuit or ground- The sensors +5 volt supply is shorted to sensor return circuit or to ground. ‪

Air Inlet Pressure Diagnostic Codes for the Series 60G Engine

Repair or Replacement of Turbocharger (Series 60 Gas Engine)

To determine if repair is possible or replacement of the turbocharger is necessary perform the following procedure. See Figure 21458 . ‪

Flowchart for Repair or Replacement of Turbocharger (Series 60 Gas Engine)

Cleaning and Removal of Turbocharger (Series 60G Engine)

Cleaning the turbocharger is not necessary before removal. ‪

PERSONAL INJURY

To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing any component.

Prior to removal, visually check for: ‪

  1. Missing or loose nuts and bolts.
  2. Loose or damaged intake and exhaust ducting.
  3. Damaged oil supply and drain lines.
  4. Cracked or deteriorating turbocharger housings.
  5. External oil leakage.
  6. Replace damaged parts with new parts.

To remove the turbocharger, perform the following: ‪

NOTICE:

Do not attempt to remove carbon or dirt buildup on the compressor or turbine wheels without removing the turbocharger from the engine. If chunks of carbon are left on the blades, an unbalanced condition will exist and subsequent failure of the bearings will result if the turbocharger is operated. However, it is not necessary to disassemble the turbocharger to remove dirt or dust buildup. ‪

  1. Disconnect and remove the elbow at the compressor housing outlet, by removing the V-band clamp.
  2. Disconnect and remove the inlet hose attached to the compressor housing inlet. To do this, disconnect the gas mixer housing two-piece bracket by removing the two bolts connecting the brackets together. Remove the mixer, bracket, and inlet piping as an assembly; set aside until re-installation.
  3. Disconnect the exhaust outlet pipe from the turbine housing of the turbocharger. For proper operation, the turbocharger rotating assembly must turn freely. Whenever the exhaust ducting is removed, spin the turbine wheel by hand.
  4. Remove the inlet oil line from the top of the center housing.
  5. Remove the oil drain line from the bottom of the center housing.
  6. Attach a chain hoist and a suitable lifting sling to the turbocharger assembly.
  7. Remove the nuts securing the turbocharger assembly to the exhaust manifold. Then, lift the turbocharger assembly away from the engine and place it on a bench.
  8. Cover the end of the oil drain line, the oil outlet line, water supply, water return, the air inlet and the exhaust outlet openings on the engine and turbocharger to prevent the entry of foreign material.

    PERSONAL INJURY

    To avoid injury from improper use of chemicals, follow the chemical manufacturer's usage, handling, and disposal instructions. Observe all manufacturer's cautions.

  9. Clean the exterior of the turbocharger with a non-caustic cleaning solvent before disassembly.

Disassembly of Turbochargers (Series 60G Engine)

Disassemble the turbocharger as follows: ‪

  1. Mark the related positions of the compressor housing, center housing and turbine house with a punch or scribe to assure reassembly in the same relative position.

    NOTICE:

    Exercise care when removing the compressor housing and turbine housing to prevent damage to the compressor and turbine wheels. ‪

  2. Loosen and remove the bolts and retaining clamps securing the compressor housing to the backplate assembly and remove the compressor housing.
  3. Loosen and remove the bolts securing the turbine housing to the center housing. See Figure 27367 .

    1. Compressor Housing ‪

    5. Center Housing Rotating Assembly (CHRA) ‪

    2. O-ring ‪

    6. Turbine housing ‪

    3. Retaining clamp (compressor housing) ‪

    7. Bolt (turbine housing) ‪

    4. Bolt (compressor housing) ‪

    Series K33 Turbocharger (Series 60G Genset, 1996 Model)

  4. Remove the turbine housing from the center housing.
Inspection and Cleaning of Turbocharger (Series 60G)

Inspect the disassembled turbocharger, discarding any damaged parts, in the following manner: ‪

  1. Visually check for nicked, crossed or stripped threads.
  2. Visually check the turbine wheel shroud and turbine wheel for signs of rubbing.
  3. Visually check the compressor wheel for signs of rubbing or damage from foreign material. The wheel must be free of dirt and other foreign material.
  4. Check the bearing axial end play:
    1. Clamp the center housing assembly in a bench vise equipped with soft jaws. See Figure 20423 .
    2. Fasten the dial indicator and magnetic clamp, part of magnetic base dial indicator set, J 7872-2 , to the center housing so that the indicator tip rests on the end of the rotating shaft on the compressor side. See Figure 20423 .
    3. Checking Bearing Axial End Play

    4. Move the shaft axially back and forth by hand. The total indicator reading (thrust float) should be 0.08-0.12 mm (0.003-0.005 in.) for K33 turbochargers. If the total dial indicator readings do not fall within the specified limits, replace the rotating assembly.
  5. Check the shaft radial movement as follows:
    1. Install the turbo shaft checker, J 39164 , to the oil drain opening of the center section. The special curved end of the tool must contact the wheel shaft through the oil outlet port and an internal opening in the center section casting. See Figure 20424 .
    2. Checking Shaft Radial Movement

    3. Install a dial indicator. See Figure 20424 .
    4. Place the swivel adaptor, part of magnetic base dial indicator set, against the scribed line of the turbo shaft checker, J 39164 .
    5. Grasp each end of the rotating assembly and, applying equal pressure at each end, move the rotating shaft first toward and then away from the dial indicator, creating a transverse movement in the shaft. The total indicator reading (radial movement) should be 0.42-0.9 mm (0.016 -0.035 in.) for K33 turbochargers. If the total indicator readings do not fall within the specified limits, replace the rotating assembly.

Assembly of Turbocharger (Series 60G)

Use the following procedure to assemble the turbocharger: ‪

NOTICE:

As the parts are assembled, cover the openings to prevent entry of dirt or other foreign material, which may cause component damage. ‪

  1. Cover all openings.
  2. Position the CHRA into the turbine housing as marked at disassembly, and line up bolt holes. Apply anti-seize compound to bolts, and torque to 20 Nm (177 lb in.).

    NOTICE:

    Always remove the compressor cover before positioning on the Center Housing Rotating Assembly (CHRA); otherwise, damage to the O-ring can result. ‪

  3. Position the compressor housing as marked at disassembly against the Center Housing Rotating Assembly (CHRA) and secure it in place with the bolts and clamps.
  4. Lightly lubricate the threads of the bolt with engine oil and torque the nut to 15 Nm (133 lb in.).

Installation of Turbocharger (Series 60G)

To install the turbocharger: ‪

  1. Attach a chain hoist and a suitable lifting sling to the turbocharger assembly.
  2. Remove any covers that were placed over the openings of the air inlet and exhaust outlet openings on the engine and turbocharger when the turbocharger was removed.
  3. Remove any covers on the oil inlet and drain lines, and the oil inlet and drain openings on the turbocharger.
  4. Place the turbocharger assembly into position on the exhaust manifold. Use a new gasket between the exhaust manifold and the turbine housing flange.
  5. Secure the turbocharger to the exhaust flange. Torque the turbocharger to exhaust manifold and locknuts to 58-73 Nm (43-54 lbft).

    PERSONAL INJURY

    To avoid injury from the sudden release of a high-pressure hose connection, wear a face shield or goggles.

    NOTICE:

    Do not use any type of lubricant on the inside of any air inlet hose or on the hose contact surfaces of the turbocharger compressor housing, CAC ducting or the intake manifold. ‪

  6. Install mixer and turbo inlet hose assembly onto the compressor inlet, and align the mixer bracket holes. Install bracket bolts and tighten.
  7. Install elbow to compressor outlet and secure with V-band clamp.
  8. Install the oil drain line, using a new gasket, between the opening in the bottom side of the turbocharger center housing and the drain hose that runs to the cylinder block. Torque the bolts to 30-38 Nm (22-28 lbft).
  9. Refer to section for verification of proper turbocharger installation.
  10. Install water supply and return lines.