TURBOCHARGER

OI GENERAL

T u r b o c h a r g e rm o d e l N o . . . . . o1-oo2
Soecif ications o1-002

0r-001
Turbocharger model No.
T h e m b d e l o f t u r b o c h a r g e ri s s t a m p e do n t h e n a m e p l a t e .
T h e m o d e l i s i n d i c a t e db y t h e f o l l o w i n g m o d e l n u m b e r s .

SPECIFICATIONS
Model
Item
K T R 1O O K T R1 1 0 K T R1 3 0 K T R 15 0

Length xWidth x Height (mm) 335x248x261 290x305x267 366x358x323 350x289x358 o

m
E
f
(ks) '19 31 f-
Weight 11 38

M a x i m u m a l l o w a b l er o t a t i o n 82.000 94,000 70,000 65.000

l\4aximumcharging (kg/min) 34 46 32 78

M a x i m u ma l l o w a b l e
''C Max.750 Max.750 Max.750 Max.750
temperature (inlet,

D i r e c t i o no f r o t a t i o n
Left hand R ight hand Rrght hand Right hand
( v i e wf r o m b l o w e r s i d e )

Forced lubrication Forced lubrication Forced lubrication Forced lubrication

L u b r i c a t i o nm e t h o d with engine oil with engine oil with engine oil with engine oil

01-002
 TURBOCHARGER
II STRUCTUREAND FUNCTION

G e n e r as lt r u c t u r.e. . . . . 1 1-002
Structureandfunction 11 - O O 4

1l-001
 .,
t
G E N E R A LS T R U C T U R E

KTRl OO

1. Flinger
2 . B e a r i n gc o v e r
3 . J o u r n a lb e a r i n g
4 . C e n t e rh o u s i n g
5 . R i n gs e a l
6. Shield
7 . T u r b i n eh o u s i n g
8 . T u r b i n ei m p e l l e r
( R o t o rs h a f t )
9. Thrust bearing
1O.Insert
1 1 . R i n gs e a l
1 2 . B l o w e ri m p e l l e r
1 3 . B l o w e rh o u s i n g
14 . R o c k n u t
a- Oil inlet(from oil filter)
b. Oil outlet (to oil pan)
c. Air inlet
d. Air outlet
l0 $ e . E x h a u s ti n l e t
f . E x h a u s to u t l e t @
'l E
1F009A f
F
V

1 . B l o w e rh o u s i n g
2 . B l o w e ri m p e l l e r
3. Clamp
4 . C e n t e rh o u s i n g
5 . J o u r n a lb e a r i n g
6. shieid
'I 7 . T u r b i n ei m p e l l e r
8. Flinger
9. Thrust bearing
1O . T u r b i n es h a f t
I 1 . R i n gs e a l
1 2 . T u r b i n eh o u s i n g
a. Oil inlet (from oil filter)
b. Oil outlet (to oil pan)
c. Air inlet
d. Air outlet
e . E x h a u s ti n l e t
6 1 6 2 F 6 0 9 A f . E x h a u s to u t l e t

r I -002
 KTRl 30

1 1 3 1 5 3 0 t 8
\ r ' r \ r - i , ' '
1 . B l o w e rh o u s i n g
2 . B l o w e ri m p e l l e r
3. Clamp
4 . C e n t e rh o u s i n g
5 . J o u r n a lb e a r i n g
6. Shield
7 . T u r b i n ei m p e l l e r
8 . T u r b i n eh o u s i n g
9. Flinger
1 O .l n s e r t
11. Thrustbearing
1 2 . T u r b i n es h a f t
a. Oil inlet(from oil filter)
r l b. Oil outlet (to oil pan)
:,Li '
lr ii I a .-l c. Air inlet
d. Air outlet
l0 il t2 e . E x h a u s ti n l e t
t.l
e f . E x h a u s to u t l e t
@ 6162F610
G
f
F
KTRl 50

1. B l o w e rh o u s i n g
2. B l o w e ri m p e l l e r
3. Clamp
4. C e n t e rh o u s i n g
5. J o u r n a lb e a r i n g
6. T u r b i n ei m p e l l e r
7. T u r b i n eh o u s i n g
8. Flinger
9. Thrust bearing
10 . T u r b i n es h a f t
a. Oil inlet(from oil filter)
b. Oil outlet (to oil pan)
c. Air inlet
d. Air outlet
e. E x h a u s ti n l e t
f. E x h a u s to u t l e t
, t
l0 e

F6'166009

r r-003
S T R U C T U R EA N D F U N C T I O N

Relative FunctionsBetween Turbochargerand Engine

T u r b i n ei m p e l l e r

Air (from air cleaner) E"t.urt

)

Blower impellel E x h a u s tg a s e s

Air outlet

T u r b i n en o z z l e
' T u r b i n eh o u s i n g
, @
E
, t! 7 T u r b i n ei m p e l l e r
F
v

Air inlet r) I Exhaust gasourle.t

a
Oil outlet

T h r u s t b e a r i n- o i
J o u r n a lb e a i l n o

lmpeller shaft t
E x h a u s tg a si n l e l

I 1-004
 Structure
. T h e t u r b o c h a r g e rh a s a t u r b i n e i m p e l l e r w h i c h r o t a t e s u n d e r h i g h - t e m p e r a t u r e h , i g h - p r e s s u r ee x -
h a u s t g a s e s .T h e n , t h e b l o w e r i m p e l l e ri n s t a l l e do n t h e s a m e s h a f t w i t h t h e t u r b i n ei m p e l l e ri s r o t a t e d ,
t h e r e b y c o m p r e s s i n ga n d s u p e r c h a r g i n gt h e i n t a k ea i r w i t h t h e e n g i n e .A s h a f t c o n n e c t i n gt h e t u r b i n e
i m p e l l e rt o t h e b l o w e r i m p e l l e ri s n o r m a l l yi n t e r g r a t e dw i t h t h e t u r b i n e i m p e l l e r .A b l o w e r i m p e l l e ri s
f i x e d w i t h n u t s t o t h e t i p o f a s h a f t o n t h e o p p o s i t es i d e o f t h e t u r b i n ei m p e l l e r .

o T h e i m p e l l e rs h a f t r o t a t e sa t a v e r y h i g h s p e e d w h i l e s u b j e c tt o t h e t h r u s t f o r c e o f t h e i n t a k ea i r c o m -
p r e s s i o n p r e s s u r ei m p o s e d o n t h e i n p e l l e ra n d t h e e x h a u s t p r e s s u r e .C o n s e q u e n t l y t, h e s h a f t i n g i s
s u p p o r t e do n a f l o a t i n g t y p e c y l i n d r i c ajlo u r n a la n d t h r u s t b e a r i n g s .

. T h e c e n t e r h o u s i n gh o l d s b e a r i n g s ,f o r m i n g t h e c i r c u i to f o i l f o r l u b r i c a t i n gb e a r i n g s .

o T h e t u r b i n e h o u s i n g c o n t a i n s t h e t u r b i n e i m p e l l e r ,f o r m i n g t h e e x h a u s t c i r c u i t . T h e e x h a u s t g a s e s
f r o m t h e e x h a u s t m a n i f o l d a r e l e d t o t h e t u r b i n e i m p e l l e ra t h i g h s p e e d a n d p r e s s u r e .T h e r e b y , t h e
g a s e s w h i c h b y t h e i r e x p a n d i n ga c t i o n r o t a t e t h e i m p e l l e ra t h i g h s p e e d a r e e x p e l l e df r o m t h e e n g i n e
i n t h i s e x h a u s tc i r c u i t .

o O n t h e o t h e r h a n d , t h e b l o w e r h o u s i n g c o n t a i n sa b l o w e r i m p e l l e r ,f o r m i n g t h e a i r i n t a k e c i r c u i t .T h e
i n t a k e a i r i s l e d t o t h e b l o w e r i m p e l l e r a n d c o m p r e s s e d b y t h e r o t a t i n g i m p e l l e r .T h e n , t h i s c o m -
p r e s s e da i r i s s u p e r c h a n r g e di n t o t h e e n g i n e .

. L u b r i c a t i o no f t u r b o c h a r g e r
o
o
G O i l i s s u p p l i e df r o n t h e e n g i n e t h r o u g h t h e t o p o f t h e c e n t e r h o u s i n g .A f t e r l u b r i c a t i n gt h e b e a r i n g s
l
a n d s l i d i n g p a r t s , t h e o i l d r a i n s t h r o u g h t h e h o l e a t t h e b o t t o m o f t h e c e n t e r h o u s i n g a n d r e t u r n st o
\z
t h e e n g i n eo i l p a n .

Notes
. R o t a t i n gs p e e d ( r e v o l u t i o n so) f t u r b o c h a r g e r s
5 O , 0 O 0t o 1 2 5 , 0 O Or p m ( c o n t i n u o u sa l l o w a b l er o t a t i n gs p e e d )
A l l o w a b l e r e v o l u t i o n sv a r y d e p r e n d i n go n t h e s i z e o f t h e i m p e l l e r .
. E n g i n ee x h a u s tt e m p e r a t u r e :5 O Ot o 7 O O ' C ( t u r b i n ei m p e l l e ri n l e t t e m p e r a t u r ei n f u l l - l o a do p e r a t i o n )

r 1-005
Function

I n a d i e s e le n g i n e ,t h e e n e r g yo f f u e l s b u r n t i n
c y l i n d e r si s i n t h e r a t i o s i n d i c a t e da t r i g h t .
The effective energy as shaft horsepower is
a p p r o x . 1/ 3 o f t h e f u e l e n e r g y .T h e r e m a i n d e ri s
e x p e l l e df r o m t h e e n g i n e .
A turbocharger takes the speed and pressure
e n e r g y o f h i g h s p e e d g a s e sf r o m t h e e x h a u s tt o
b e e x p e l l e df r o m t h e e n g i n ew i t h t h e t u r b i n ei m -
peller as the rotating power source. Thereby,
t h e b l o w e r i m o e l l e ro n t h e s a m e s h a f t w i t h t h e
t u r b i n e i m p e l l e ri s r o t a t e d s o t h a t t h e a i r i s c o m -
pressed and supercharged into the engine.
In order to obtain the effective horsepower
i n a d i e s e le n g i n e ,a q u a n t i t yo f a i r a p p r o x . 1 7 t o
22 times greater than the amount of fuel to be
i n j e c t e d i s g e n e r a l l yr e q u i r e d .T h i s c o r r e s p o n d s
t o 1 . 2 t o 1. 5 t h e e x c e s sa i r r a t i o .

Note
@
E x c e s sa i r r a t i o : E
l
The ratio of the quantity of air necessary F
Y
t o a c t u a l l yo b t a i n o p t i m u m c o m b u s t i o n e f f i -
c i e n c y .a s s u m i n gt h a t t h e t h e o r e t i c a lq u a n t i -
t y o f a i r r e q u i r e df o r c o m p l e t e f u e l c o m b u s -
tion is 1. For combustion in a dieselengine,
an excess air ratio of 1.2 to 1.5 is required
becauseof the fuel mist-air mixture, com-
b u s t i o nt i m e l i m i t , e t c . l f t h e q u a n t i t y o f a i r i s
less than 1.2 to 1.5 the excess air ratio, in-
complete combustion will take place, re- and atter cooli
sulting in black exhaust smoke and an in-
q ,/

c r e a s e dh e a t l o a d .
3
o
I n a t u r b o c h a r g e de n g i n e , a q u a n t i t y o f a r r
o
c o r r e s p o n d i n gt o t h e f u e l i n i e c t i o n q u a n t i t y i s
c o m p r e s s e da n d s u p e r c h a r g e d l.n a n e n g i n e o f c
o
t h e s a m e c y l i n d e rc a p a c i t y ,t h e h o r s e p o w e rc a n c
U
b e i n c r e a s e da s i n d i c a t e di n t h e g r a p h a t r i g h t . l f
aturally aspirated(not turbocharged)
an after-cooleris used with the turbocharger.
t h e h o r s e p o w e rc a n b e f u r t h e r i m p r o v e d .
'1400 1600 1800 2000 2200
1200
E n g i n es p e e d( r p m )
Comparisonof horsepowerbetween turbocharged
a n d n a t u r a l l ya s p i r a t e de n g i n e( N T A 8 5 5 e n g i n e ) .

I I -006
 TURBOCHARGER
1:} DISASSEMBLY AND ASSEMBLY

GENERAL
Disassembly
Assembly ..

r3-001
TIGHTENINGTOROUE(STANDARDI
When assembling the turbocharger, tighten
to the tollowing tightening torques, ancl
checkthat the end playis within the standard
value.
Coat the bolts marked 't with anti-friction
comoound (LM-Pl.

1 l
@
E
l
F
Y
6162F402 18 6162F402-3

No I tem
-r,oo [
"r-ffi
1 End play (play rn axial direction) 0 . 0 6- ' 0 . 11 0 . 0 8- 0 . 1 3 0 . 0 8- 0 . 1 3 0 . 0 8- 0 . 1 3
mm mm mm

2 R a d i a lp l a y ( p l a y i n r a d i a ld i r e c t i o n ) 0 . 2 0- 0 . 4 0 0 . 2 5- 0 . 4 4 o . 2 5- O . 4 4 o . 2 5- O . 4 4
mm mm mm mm

Clearance between blower housing

3 M i n0 . 1 5 l V l i n0 . 2 0 lvlin0.20 M i n0 . 2 0
and inpeller mm mm mm mm

T i g h t e n i n gt o r q u e o l b l o w e r i n p e l l e r
A 4 . 2 5t 0 . 2 5 , a + n ? 8 . 5t 0 . 5 o q + o E
Iocknut kgm Kgm

Tightening torque of difluser (insert)

6
1. 2 5 L O . 2 5 3 . 15 t 0 . 3 5 1 . 3 51 0 . 1 5 6 . 7 51 0 . 7 5
mounting bolt kgm Kgm kgm kgm

T i g h t e n i n gt o r q u e o f t u r b i n e h o u s i n g 5.0 I 0.5 5.75 t 0.25

6 m o u n t i n gb o l t kgm
kgm

7 T i g h t e n i n gt o r q u e o f V b a n d l @ k n u t 0 . 9t 0 . 1 0 . 9t 0 . 1 0.9t 0.1 0.9t 0.1

Kgm kgm kgm kgm

13-002
GENERALDISASSEMBLY

. Before disassembling the turbocharger, Replace the entire rotor assembly, if the
clean its outside surface and apply match d y n a m i c b a l a n c ec h e c k o n t h e r o t o r a s s e m -
m a r k s t o e n s u r et h a t t h e b l o w e r h o u s i n ga n d bly is impracticable.
t u r b i n e h o u s i n ga r e r e a s s e m b l e di n t h e i r o r i g -
i n a lo o s i t i o n s . B e f o r e d i s a s s e m b l i n gt h e t u r b o c h a r g e r a s -
s e m b l y , m e a s u r e t h e r a d i a l c l e a r a n c ei n t h e
f o l l o w i n g m a n n e ra n d k e e p t h e m e a s u r e m e n t
on recoro.
1 ) D e p r e s st h e f r o n t e n d o f t h e r o t o r i n t h e
r a d i a ld i r e c t i o nw i t h a f i n g e r .
2) Measure the clearance between the
b l o w e r i m p e l l e ra n d t h e h o u s i n g b y u s i n g
f i l l e rg a u g e O . ( S e eP 1 )

1. Housing
* When removing the blower housing and
t u r b i n e h o u s i n g ,t a k e c a r e n o t t o d a m a g e
t h e b l o w e r i m p e l l e ra n d t u r b i n ei m p e l l e r .

F o r K T R1O 0 , K T R13 0
1 ) R e m o v e t h e n u t a n d c l a m p ( ' l) , ( 2 ) .
( S e eP 2 )
o
2l Remove turbine housing (3) and @
G
b l o w e r h o u s i n g( 4 ) . ( S e eP 2 ) l
F
Y

F o r K T R ' l1O , K T R15 0

1) Remove the nut and V-band clamp
( 1 ) .( S e eP 3 )
2 l R e m o v eb l o w e r h o u s i n g ( 2 ) . ( S e eP 3 )

3 ) Straighten the lock washer, remove

mounting bolts (3), and then remove
lock plate. (See P4)
4) R e m o v et u r b i n eh o u s i n g ( 4 ) . ( S e eP 4 )

r 3-004
 KTR1OO,KTR130

3
6
I -lr-r
r$ -a\ t
"
,rlo A"^;!"
|3 - rto'"l)

ov

@
E KTR 11O,KTR150
:)
F
3
." *;s l
''
r4 LLi9
's-" to
4 ll 1OP)",,
noP-

6;*"
'=8&
\
850T0P000 1

r 3-00s
 * B e f o r e r e m o v i n g t h e b l o w e r i m p e l l e r s ,m e a - 3. Insert (Back plate)
s u r e t h e e n d p l a y a n d t h e r a d i a lp l a y o f t h e o ForKTR1OO,KTR130.
rotor assemblyin the following manner and 1) Straighten the lock washer and
k e e p t h e m e a s u r e m e n t so n r e c o r d . r e m o v eb o l t .
1 ) M e a s u r e m e n to f t h e e n d p l a y ( A p l a y i n 2l Alternately drive two bolts into the
t h e a x i a ld i r e c t i o n ) tap holes of the insert (7) to remove
i) Set dial gauge @ in position. (See i t . ( S e eP 5 )
P1)
ii) Read the dial gauge indicatorwhen
the rotor assemblv is moved in the
a x i a ld i r e c t i o n .

2 ) M e a s u r e m e not f t h e r a d i a lp l a y ( A p l a y i n . F o r K T R 1 1 0 ,K T R 1 5 0 .
theradialdirection) 1) Straighten the lock washer and
i) Set dial gauge @ in position. (See r e m o v eb o l t .
P2l 2l Remove turbine rotor from the back
ii) Read the dial gauge indicatorwhen p l a t e ( 7 ) .l S e eP 6 )
the rotor assemblvis moved in the
r a d i a ld i r e c t i o n .

o
6
E
f
2. Blower impellers 4. Flinger F
u
1) Clamp the end of the turbine rotor in a 1) Pull out flinger (8) from the insert (back
vice. p l a t e ) ( S e ep 7 )
* Securely clamp the turbine rotor in 2l Remove seal ring (9) from the flinger.
the vice so as to prevent it from (See P8)
overturning or from falling.
2 ) L o o s e na n d r e m o v e n u t ( 5 ) . ( S e eP 3 )

3 ) E x t r a c t t h e b l o w e r i m o e l l e r sf r o m t h e t u r -
binerotor in the followingmanner.
i) l m m e r s e t h e r o t o r a s s e m b l yi n t h e o i l 5' Thrust bearing
.l
that is heatedat 40 to 16O"Cfor 5 R e m o v et h r u s t b e a r i n g( l O ) .( S e ep 9 )
to 20 minutes.
i i ) E x t r a c t b l o w e r i m p e l l e r s( 6 ) f r o m t h e
turbine rotor. (See p4) 6. Thrust collar
* W h e n e x t r a c t i n gt h e b l o w e r i m - R e m o v et h r u s t c o l l a r ( 1 I ) . ( S e eP 1 0 )
peller, take care not to apply an
excessiveforce to the imoeller.

r 3-006
 .]'' 'r
Check tor a play in
I the axral direcrron

) , u ro r o t

P2

J,/
a'

\dF,
V
w
w'
wE
1 /

l3-007
 7. Center housing
P u l l o u t c e n t e r h o u s i n g ( 12 ) f r o m t h e t u r b i n e
r o t o r . ( S e eP 1 )
* Take care not to damage the journal
bearing.

8. Journal bearing
Remove journal bearing (13).(SeeP2)

9. Shield
Remove shield (14) from the turbine rotor
( S e eP 2 )

o
E
f
1O. Turbine rotor
Y
Remove two seal rings (16) from turbine
r o t o r ( 1 5 ) . ( S e eP 3 )

r 3-008
 w@*

o
o

5 P 3
F
Y

..16

r 3-009
G E N E R A LA S S E M B L Y
. Before assembly parts, wash and clean the 5 . Thrust collar
parts, allow them to dry by air blow, and 1 ) I n s t a l lt h r u s t c o l l a r ( 1 1 ) . ( S e eP 4 )
a p p l y e n g i n eo i l t o t h e s l i d i n gp a r t s . * Make sure that the thrust collar is
. Remove burrs completely from the parts. f ree f rom foreign matter on both
(Pay attention to seal ring grooves. in sides. apply engine oil to both sides
particular.) of the collar, and Install the collar
* W h e n r e a s s e m b l i n gt h e r o t o r a s s e m b l ya f t e r with the match mark aligning with
t h e d y n a m i c b a l a n c ec h e c k h a s b e e n m a d e , the matingmark.
be sure to alignall the match marks stamped 2 ) D r i v ea d o w e l p i n i n t h e c e n t e rh o u s i n g .
o n t h e c o m p o n e n tp a r t s .
6 . Thrust bearing
I n s t a l lt h r u s t b e a r i n g ( 1 O )w i t h t h e d o w e l p i n
1. Turbine rotor
f i t t e d i n p o s i t i o n .( S e eP 5 )
2 ) F i t s e a l r i n g s ( 1 6 ) i n t o t u r b i n er o t o r ( 1 5 ) .
* B e f o r e a n s t a l l i n gt h e t h r u s t b e a r i n g ,a p p l y
{ S e eP 1 )
e n g i n eo i l t o b o t h s i d e so f t h e o i l h o l e .
* A p p l y a c o a t o f e n g i n eo i l t o t h e s i d e
o f s e a l r i n g s a n d i n s t a l lt h e s e a l r i n g s
7 . Flinger
in such a way that the gap of each
1) Fit seal ring (9) into ftinger (8). (See p6.
r i n g i s p o s i t i o n e da t 1 8 O ' a p a r t f r o m
Pll
t h a t o f t h e n e r g h b o r i n gr i n g . r Apply engine oil to the sides of the
s e a lr i n g .
2 ) I n s t a l lf l i n g e r i n t o t h e i n s e r t( b a c kp l a t e )
* Let the gap of the seal ring on the
flinger direct to the oil filler port on o
t h e c e n t e rh o u s i n g . 6
E
l
2. Shield F
I n s t a l ls h i e l d { 1 4 ) i n t o t h e t u r b r n er o t o r . ( S e e 8. I n s e r t ( 8 a c k p l a t e )
P2l o FoTKTRIOOKTRl30.
1) Fit an O-ring and install insert (7).
( S e eP 8 )
Journal bearing 2l Tighten the insert mounting bolts
I n s t a l l . l o u r n able a r i n g( 1 3 ) . ( S e eP 2 ) and then bendthe lock washer.
't Apply sufficient amount of engine oil to
t h e i n s i d e ,o u t s i d e ,a n d b o t h s i d e s o f t h e
j o u r n a lb e a r i n gp r i o r t o t h e i n s t a l l a t i o n .

4. Center housing F o r K T R1 1O , K T R ' l5 0

Install center housing (12) on the turbine 1) I n s t a l lt h e t u r b i n e r o t o r o n t o t h e b a c k
rotor. (See P3) p l a t e ( 7 ) . ( S e eP 9 )
* W h e n i n s t a l l i n gt h e c e n t e r h o u s i n g , t a k e
2l Tighten the back plate mounting
c a r e t o p r e v e n tt h e s e a l r i n g f r o m s l i p p i n g bolts and bendthe lock washer.
out.

r 3-010
 P4

P1 P6

n
il
rf

\K
-{i
i+\

650T0P0004

r 3-0r1
9. Blower impellers 1 0 Housing
l) lnstall blower impellersonto the turbine * Take care not to damage the blower im-
rotor in the followingmanner. p e l l e r a n d t u r b r n ei m p e l l e rw h e n i n s t a l l i n g
il lmmerse blower impellers (6) in the t h e b l o w e r h o u s i n ga n d t u r b i n eh o u s i n g .
o i l t h a t i s h e a t e d a t 14 0 " t o 1 6 0 " C
for 5 to 20 minutes. . F o r K T R1O O .K T R13 0 .
i i ) I n s t a l l t h e b l o w e r i m p e l l e r so n t o t h e 1 ) I n s t a l lt h e b l o w e r h o u s i n g ( 4 ) a n d t u r -
turbine rotor. aligning the match b i n e h o u s i n g ( 3 ) i n t o t h e c e n t e rh o u s -
m a r k .( S e eP 1 ) i n g a n d t h e r o t o r a s s e m b l y .( S e eP 5 )
* Apply engine oil to the inner 2 l T i g h t e n c l a m p ( 2 ) . ( 1 ) . ( S e eP 5 )
f a c e o f t h e b l o w e r i m o e l l e ra n d
install the imoeller without
u s i n g a n e x c e s s i v ef o r c e .

2 ) T i g h t e n n u t ( 5 ) . ( S e eP 2 ) F o r K T R1 10 , K T R15 0 .
* When tightening the nut. take care 1) Install the turbine housing (4) into
not to allow anv of match marks to the center housing and the rotor as-
be out of alignment. s e m b l v .( S e eP 6 )
2 ) Install lock plate, tighten mounting
bolt (3), and bend the lock washer.
( S e eP 6 )
3) I n s t a l l b l o w e r h o u s i n g ( 2 ) a l i g n i n g i t
w i t h t h e c e n t e rh o u s i n ga n d t h e r o t o r
a s s e m b l y .( S e eP 7 )
* Apply a thin coat of grease o
( G 2 - L l )t o t h e f l a n g e s e c t i o n . @
G

M e a s u r et h e e n d p l a y a n d t h e r a d i a l p l a y o f 4 l T i g h t e nV - b a n d c l a m p ( 1 ) . ( S e eP 7 ) l
F

t h e r o t o r a s s e m b l yi n t h e f o l l o w i n g m a n n e r .
1 ) M e a s u r e m e n to f t h e e n d p l a y ( A p l a y i n
t h e a x i a ld i r e c t i o n )
i) Set dial guage @ in position. (See
P3)
ii) Read the dial gauge indicatorwhen
the rotor assembly is moved in the
a x i a ld i r e c t i o n .

2 ) M e a s u r e m e n to f t h e r a d i a l p l a y { A p l a y i n M e a s u r et h e c l e a r a n c ei n t h e r a d i a ld i r e c -
t h e r a d i a ld i r e c t i o n ) t i o n i n l h e f o l l o w i n gm a n n e r .
i) Set dial gauge@ in position. (See 1) Depress the end of the rotor in the
P4) r a d i a ld i r e c t i o nw i t h a f i n g e r .
ii) Read the dial gauge indicatorwhen 2 l M e a s u r e t h e c l e a r a n c eb e t w e e n t h e
the rotor assembly is moved in the blower impeller and the housing by
r a d i a ld i r e c t i o n . u s i n g f i l l e rg a u g e @ . ( S e eP 8 )

A f t e r c o m p l e t i n gt h e a s s e m b l y ,r o t a t e t h e
r o t o r a s s e m b l y w h i l e d e p r e s s i n gi t l i g h t l y
and make surethat the rotor can be rotat-
ed smoothlywithout binding.

13-0.|2
 ,#, -ro -t'

U 6s0T0P0003

i.'\*

650T0P0001

6
E P ?

F
v
 TURBOCHARGER
t4 STANDARD AND
MAINTENANCE
I N S P E C T I O NO F P A R T S

M a i n t e n a n c es t a n d a r d
K T R010 . . .. . . . . 14-OO2
K T R110 . . . . . . . . 14-OO3
KTR130........ 14-004
K T R510 . . . . . . . 14-OO5
Inspectionof parts 14-OO6

r 4-00r
TURBOCHARGER
KTRl OO

A
14F001

Unit:mm

C h e c ki t e m Criteria Romsdv
m
E
Standard R s p a i rl i m i t Raplacing parls l
End play {playin axaal F
direclion) relatod to thrust Y
0 . 0 6r o 0 . 11 I 0.18

Radial play {play in radial acing parts

2 0.2o to 0.O4 0.60
direction) to bearing

Tolerance R e p a i rl i m i t
Outside diameter of journal
Shaft Hole Sha ft Hole
3 beanng
lnner diameter of center housing o.040 +0.020
24 0_060 0 23.91 24.O4

Inner diameter of Journal bearing -0.030 +0.020

15.94 16.05
Outside diameter of wheel shaft 0.050 0
Bend of wheel shafl R s o a i rl i m i t : 0 . 0 1 0 l T o t a l i n d a c a t e dr u n o u t )
Tolerancg R o p a i rl i m i r
Roplacs
Width Groove width Groove
5 Thickn6s of thrust bearing
-0.08 0
5.5 -o.o2 5.34 5.52

Turbine -0.08 0.o3

2 -0.04 r.85 2.05
sroe 0.10
-0.08 'l.85
6 Thickne$ of seal ring
2
Elower -0.'t 0
srde
-0.'t3 4.05

Clearance between blower Roplace pans

7 T o l e r a n c e ( m i n . )0 . l 5 related to be€
housing and impeller

Tightening torque of blowor

8 4.25 1 0.25 kgm
imoeller locknut
Tighlening torque of insen Tighton
I 1.25I 0.25 kgm

Tightening torque ot V band

10 o 9 10.1ksm

t4-oo2
 KTR1 1 O

I I i l 2 6
i , , ' /
z\'\
/ .F'<
tn\
rt\ li\ X

t0

6162F402-1 A 6162F402-2
U n i t :m m

NO Check itsm Criteria Remedy

@
E
l End play (playin axial StandErd R e p a i rl i m i
F Raplaceparts
Y directionl
0.08 to 0.13 0.18 rslated to thfl

Radial play (play in radial Baplace parts

di rectionl
0.25 to 0.44 0.60
related to beal i n g

Tolerance R e o a i rl i m i t
Outside dismgt€r of journsl
Shaft H ole
3 boarang Shaft Hole

Inn€r diamoter ot c€nt€r housing 0.040 +o.o2

23 22.92 23.O3
0
Inner diameter of Journal bearing. -0.032 +0.009
Oulside diameter ol wheel shaft. 4.95 I 5.04
0.043 { 003
Bond ot wh€el shaft R e p a i rl i m i t : 0 . 0 1 0 ( T o t 6 l i n d i c a t e dr u n o u t )
Replace
Tolerance R e p a i rl i m i t
G widrh
5 Thicknessof thrust bearing
0.08 1O.O2
5 ,0 11 4.86 5.04
T u r b in e 0.08 0.03 L85
stde 2 2.O5
6
Slower -0.08 0.03
-o 04 1 .45 1.65
0.10
Clearanco botwe6n blower Replace parG
7 T o l e r a n c e :( m i n . ) 0 . 2 0
housing and impeller felated to bear

Tightening torque of blower

8 imoeller lo.kn,,r
2.9 r 0.3 kSm

Tightening torque of ditluser

I r. rc ru Jc Kqm
Tighten
Tightening torque of V band
10 locknut 0 . 91 o . t t s -
Tightening torque oI turbine
l1 housing bolt 5.0 1 0.5 kgm

r4-003
KTRl30
s

,[u'
2 3 1 t0
6162F402
6162F401

Chsck item Cr i t e r i R omedV

Standard R epair limit Raplacepans

'I End play {play in axi€l related to
direction) 0 . 0 8t o 0 . 1 3 thrust o
0.18
E
l
Radial play (Play in radial 0.60 related to F
2 diredionl 0.25to 0.43 )Z

Tolerance R e p a i rl i m i t

Outsido diamet€r of iournal Shaft H ole Shaft H ole

3 bearing.
I nner diameter of center housing 0.060 0.020
30 29.89 30.04
0.080 0

I nngr diamster of journal bsaring. -0.030 +0.0'15 19.95 20.05

Outside diamet€r of whoel sha{l. 20 0.045 0

Eend of wheel shaft R € p a i rl i m i t : 0 . 0 1 0 ( T o t 6 l i n d i c a t a dr u n o o l ) Replee

Tole16nc€ R e p o i rl i m i t
Strndard size
Width Groove width Groove
5 Thicknessof thrust bearing
,0.08 +0.02
6 - 0 . 11 5.86 6.04
0

0.08 -0.03
2.85 3.05
6 Thicknossof seal ring 3 0.10 0.04
Replacoparu
Clearance betwoen blow€l
T o l e r a n c e :( m i n . ) 0 . 2 0 related to
7 housing and impeller

Tightening lorque of blower

8.5 10.5 kgm
I impoller locknut

Tightening torque of insert 1 . 3 5: t 0 . 1 5 k g m

T ighten
9 mounting bolt
Tighl€ning torque of V bsnd
1 0 locknut 0 . 91 0 . 1 k s m

t4-oo4
 t0
KTRl 50

F6 166056

No Check item Critsria Remedy

Standard R e p a a rl i m i t Raplace
End play {pl6y in axial
diroction) 0.08to 0.13 0.18 thrust

R6dial play (Play in axial Raplace p,

0.25to 0.43 0.60 related io

2 d irection )
beanng

@ Tolerance B e p a i rl i m i t
E
l Outside diameter of iournal
F beaflng. ShBft H ol0 Shatt H ole
v 3 Inner diameter of center
0.060 +0.o20
housrng. 30 29.89 30.04
0.080 0

Inner daameter of journal bearing ..0.030 +0.01

5
20 -0.045 19.95 20.05
Outsid6 diam€ter of wheel shsft. 0
4
Bend of wheel shafl R e p a i rl i m i r : 0 . 0 1 0 { T o r a l i o d i c a t e dr u n o u t ) Replace

Toleranco R o o a ; rl i m i t

width Groove Width Groov€

5 Thickness of thrust bearing
0.08 +0.02
-0.11 5.86 6.04
0

0.08 -0.03
6 Thickness of seal ring 3 -0.04 2.45 3.05
0.10
Clesrance betwoen blower Roplacep
1 T o i s r a n c o :( m i n - )0 . 2 0 related to
housing 8nd imp€ller

Tightening torqus ot blowor

8 9.5 IU 5 kgm
imDgller locknut
Tightening torque of inserl
mounting bolt 6.76 1 0.75 ksm
Tighten
Tight6ning torqu€ of turbino
r0 housing bolt 5.75 t 0.25 kgm

Tightening torquo of V band

0 . 91 0 . 1 k s m
loc Knut

l4-005
Inspectionof parts and judgementstandards
paying
. I n o r d e r t o m a k e c o r r e c t d i a g n o s e so f f a u l t y p a r t s , f r r s t c l e a n t h e p a r t s ,t h e n I n s p e c tt h e m '
s o e c i a la t t e n t i o nt o t h e f o l l o w i n g c h e c k p o t n t s

Part Check points Parl Check points

Blower housing B l o w e ri m p e l l e r a Damage or bending ot the

a Contact with blower
blade
rmpeiler
a Contactwith blower housrng
a Damage or deformation oj
the surface fitted with the
cenTerhousing
o Deformatron or tailure at
jo!n ts Journal bearinq
a S c u f f i n ga n d s e i z u r e
I Wear

Center housing
ffit
a Failure or wear at scal
bo re
a Scratches at bearing bore Thrust beailng
a Deformat on or failure a1 a W e a ra n d c r a c k s
lornts

T u r b i n eh o u s i n g
a Contact with turbine rotol
Shield
o Corrosion of the lnner surface o
a Wear and cracks o
r
l
F

T u r b i n es h a t t o Damage or wear of the seal

ring portion of the shajt
Flinger
a Wear, drscolorat on and
and thrust collar a Discoloration
seizure of the joLrrnalportion

o o o Wear of the surface in contac

ot the shait
o wlth the back plate
Bend of the shatt

a F o r c r i t e r i a a b o u t w e a r a n d b e n d i n g , r e f e r t o t h e l v l a i n t e n a n c es t a n d a r d

14-006
 Standardsfor Reuseof Parts

e U s e t h e p h o t o g r a p h si n t h e s h o p m a n u a l ( S E B G 4 0 8 Oa) s r e f e r e n c ew h e n m a k i n gj u d g e m e n t .

Failure degree

Part L o c a t r o no r t y p e
U s ea f t e r
name of failure U s ea g a i n D o n o t u s ea g a i n
reconditioninq
I n n e r s u r f a c eo l Light contact flaw not Flaws other than use Flaw extending over
I b l o w e rh o u s i n g extending over the again and do not use the entire inner
entire inner surface. agatn. surface.
c
6 Surface fitted to the No damage or T h e c o n t a c t i n gs u r f a c e T h e r ei sc l e a r a n c ewith
l
o center housing. detormati on. h a sa f l a w b u t d o e sn o t t h e c e n t e rh o u s i n g
E 2
a l l o wa i r t o l e a k . c a u s e db V d e t o r m a t i o n
3
o
m
s t air
Connectiona N o d e t o r m a t i o no r [Iinor deformation Morefaulty condition
3 inletandoutlet parts. c r a ck s . w h i c h d o e sn o t a l l o w t h a n i n u s ea f t e r r e -
a r rt o l e a K . c o n di t i o ni n g .

Surface contacting No scratches Very thin wear Large scratcnes.

I
journal bearing. Wear.

Surface contacting No scratches. G o i n gt o s e i z e .

- !
2 seal ring. H e a v yc a l k i n g .

Flaw due to contact Light contact flaw no1 S l i g h ts e i z u r eo n t h e C o n t a c tf l a w e x t e n d i n g

I with turbine rotor. extending over the c o n t a c ts u r t a c e . o v e r t h e e n t i r ec i r -
@
E
l
whole circumference. cumference.
F
Y R e m o v a b l ec o r r o s i o n . C o r r o s i o na c c o m p a n i e d
C o r r o s i o no r o x i d a t i o n No corroded or
l
o o f t h e i n n e rs u r t a c e . oxidized surface w i t h c r a c k so r u n -
E 2
r e m o v a b l eo x i d e f i l m .
c
b
f
F D e fo r m a t i o n . W h e n f l a t n e s so f t h e W h e n t h e r ei s a p o s
i n l e t f l a n g ei s l e s s s i b i l i t yt h a t t h e t u r b i n e
3 w h e e lw i l l c o m e i n t o
t h a n0 . 3 m m .
c o n t a c tw i t h t h e
housrng.

| 4-OO7
 F a i l u r ed e g r e e
Part Locatron or type
Use after
name of failure U s ea g a i n D o n o t u s ea g a i n
r e c o n di t i o n in g

B e n d i n gd
, eformation T h e r e i s a s l i g h tb e n d C r a c k s ,l a c k o f m e t a l a t
of the blade. b u t n o c r a c k sa t t h e t h e t i p , e a s i l yo b s e r v -
Jio a b l eb e n d .

Flawdue to contact T r a c eo f s l i g h tc o n t a c t B u r r so r d e J o r m a t i o n
b e t w e e nb l a d ea n d ison the wholesurface
2 housing. of the blade.
However,there are no
ourrs.

Seal ring groove No wear or damage Deformation to the

point that the seal
3
ring isstuck.

JOUrnal No discoloration. D i s c o l o r e ds u r f a c ec a n D i s c o l o r a t i o no t h e r
( d i s c o l o r e d) b e e a s i l yr e m o v e dw i t h than use after
c 4 No. 400 to No. 600 r e c o n di t i o n i n g .
.t s a n dp a p e r .
!
) Scratchesnot One or two flaws F l a w so t h e r t h a n u s e
F Journal
(flaws) d e t e c t a b l eb y f i n g e r n a i l w h i c h c a t c h o n n a i l s afterreconditioning.
5 (Such flaws need not
be repaired.)

6 J o u r n a l{ s e i z u r e ) No seizure No seizure S e i z e db e a r i n gm e t a l .

B e n do t t h e s h a f t O . 0 1 m mo r l e s sT . l . R E x c e e d i n g0 . 0 1 m m
7 (Totalindicated T . t .R .
runout) @
E
f
Surfaceof fitted N o s c u f f i n go r f l a w The surface has a flaw F
Y
portion of a blower or scuffed area due to
8
impeller. the turned impeller.

Shaft back surface No trace of conlact There is evidence of

9 contact.

M a r k e db e n d i n go f t h e
Bend of the blade tip S l i g h tb e n d i n go f t h e
1 trp.
tlp.

Cracksor damageol No cracks or damage Cracks or damage.

a
the blade.

Contact between blacle There is a trace ol There is contact that C o n t a c to t h e r t h a n u s e

3 and housing. s l i g h tc o n t a c t . can be easily removed againand useafter re-
I with sandpaper. cLnditioning.
o
q Contact with the back No contact No contact Contact.
4
plate.
3
I Damage ot the contact No damage No damage Damage.
@
5 surface with nut.

D a m a g eo f i n n e rs u r f a c e N o d a m a g e No damage Damage.
o
o t s h a f th o l e .

Flawon the contact No flaw. No flaw. Flaw.

1 s u r f a c ew i t h t h r u s t
c o lIa r .

14-008
 F a i l u r ed e g r e e
Part Locatron or type
name o f f a il u r e Use after
U s ea g a i n D o n o t u s ea g a i n
reconditioning

1 Cracks No cracks No cracks. Cracks.

Contact surfacewith F l a w t h a t c a t c h e so n Marked degree of

t h r u s tc o l l a r . f i n g e r n a| i. wear or flaw.
!
Contact with the No chattering No chattering, Chattering
c e n l e rn o u s r n g .
o
( B e a r i n gi s c h a t t e r i n g )

4 Oil hole. No clogging. No clogging. Clogged.

Contact surfacewith W e a ro r f l a w s o n t h e Wearinggrooveson the

t h e b a c kp l a t e . c i r c u m f e r e n c teh a t d o surfacethat catch on a
n o t c a t c ho n a f i n g e r n a i l . f i n g e r n a| i.
!
o
T h e r m a ld i s c o l o r a t i o n . No discoloration No discoloration. P a r t i a ld i s c o l o r a t i o n .
I

J Wear or damageol N o w e a ro r d a m a g e . No wear or damage Wear or damage.

end surfaces.

Cracks. No cracks. No cracks Cr a c k s

Wear Withinthe standard Within the standard Out of the standard

- n
( t h i c k n e s)s range. range. range.

@
c
f
F
Y

r 4-009