W200/W220

15
Turbocharging and air cooling

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 W200/W220

Turbocharging and air cooling .............................................................................................................................3

15.1 Twin turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

15.1.1General description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
15.1.2 Operation mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
15.1.3 Removing and installing the turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
15.1.4 Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
15.1.4.1 Oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
15.1.4.2 Lube oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

15.1.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
15.1.5.1 Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
15.1.5.2 Cleaning operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

15.1.6 Maintenance works (M1, M2, M3 codes, see Chap. 04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

15.1.6.1 To clean the turbocharger, dismantle the silencer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

15.1.7 Filtering cover for turbocharger TPS52 and TPS57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

15.1.8 V-clamps for turbochargers TPS52 and TPS57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
15.1.8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
15.1.8.2 Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

15.1.9 Cleaning the compressor (fig.15-08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

15.1.10 Removing and installing the cartridge group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

15.2 Charge air circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

15.2.1 Air cut-off valves (in option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
15.2.1.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

15.3 Charge air cooler maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

15.3.1 General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
15.3.2 Cleaning of the charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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15. Turbocharging and air cooling

15.1 Twin turbocharger
15.1.1 General description
Data and dimensions The function of a turbocharger is to use the exhaust gas energy of
Weight (dry) : TPS52 : ~ 200 kg an internal combustion engine (which would otherwise be wasted).
TPS57 : ~ 310 kg The compressor increases the pressure and density of the charge air
Inlet turbine maxi. temp : 650 °C in the engine cylinder, thereby increasing the power above that of
Maximum turbine speed :
TPS52 : 49900 rpm
an atmospheric engine.
TPS57 : 40900 rpm

15.1.2 Operation mode

Fig. 15-01

The turbocharger consists in two machines : a radial turbine and a

radial compressor mounted on a common shaft.

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 15. Turbocharging and air cooling W200 Ph2/C/D, W220 PhC/D

The exhaust gases from the diesel or gas engine flow through the
gas outlet casing (item 10) and nozzle ring (item 9) to the turbine
wheel.
The turbine wheel (item 7) uses the energy contained in the exhaust
gases to drive the compressor (item 13), whereby the compressor
draws in fresh air, compresses it before being forced into the cylin-
ders.
The exhaust gases exit the turbocharger via the gas outlet channel
(item 8).
The turbocharger is gastight.
The air necessary for the operation of the diesel or gas engine and
which is compressed in the turbocharger, is drawn through the suc-
tion branch or the silencer (item 1) into the compressor wheel (item
13 ). It then passes through the diffusor (item 3) and leaves the
turbocharger through the volute of the compressor casing (item 14).
The rotor runs in two radial plain bearings (items 5/6) located in the
bearing bushes (items 11/12) between the compressor casing and
turbine casing.
The axial thrust bearing (item 5) is located between the two radial
plain bearings.
The bearings are connected to a central lubricating oil feed in which
the oil is supplied by the oil system of the engine.
The oil outlet is always at the lowest point of the bearing casing
(item 4).

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 W200 Ph2/C/D, W220 PhC/D Turbocharging and air cooling 15.

15.1.3 Removing and installing the turbocharger

1 Disconnect all air lines from the external filter (oil bath fil-
ter) and exhaust gas silencer.
2 If provided : Remove the turbocharger insulation.
3 Disconnect all oil and water pipes.
4 Check the lifting equippment.

Turbocharger without gas Attach lifting equippment to the bearing casing.

outlet elbow :

Fig. 15-02

Caution : Consider the weight of the turbocharger when selecting a suitable

rope. Note the centre of gravity.

5 Release fixing screws on bearing casing.

6 Lift the turbocharger from the engine.
7 Cover oil connections.
To install the turbocharger, follow the instructions in reverse order.

Note : Always use new gaskets.

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 15. Turbocharging and air cooling W200 Ph2/C/D, W220 PhC/D

15.1.4 Lubricating
15.1.4.1 Oil supply
A properly designed oil supply, suitable for all modes of operation, is
an important prerequisite for trouble-free operation of the turbochar-
ger. The lubrification of the TPS turbocharger is provided by the lube
oil from the engine lube oil circuit.

Warning : Please follow strictly the lube oil list given in Chap. 02, in which you
will find the approved products . If not, no warranty should be taken
into account.

15.1.4.2 Lube oil Pressure

The lube oil pressure is provided through the turbocharger holder,
the pressure is calibrated by an orifice at the connection level with
the turborcharger holder.

15.1.5 Maintenance
15.1.5.1 Daily inspection
Inspection work during operation includes visual checks, as well as
monitoring and measuring in order to ensure the correct functioning
of the turbocharger. This serves as an aid for the recognition of de-
viations during operation in order to prevent damage to the ma-
chine.

Note : Control and measurement checks must be carried out on the listed
inspection points at the intervals quoted, see maintenance schedule
chap. 04.

15.1.5.2 Cleaning operation

Regular cleaning should ensure fault-free operation of the turbo-
charger and its fittings.
The filter rings should be washed every week.
The external conditions have big influence on the degrees of con-
tamination of the cleaning points listed below. The intervals
quoted in the maintenance schedule can be reviewed in conse-
quence.

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 W200 Ph2/C/D, W220 PhC/D Turbocharging and air cooling 15.

During all cleaning work, the safety instructions must be observed.

Visual check

Washing

Fig. 15-03

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 15. Turbocharging and air cooling W200 Ph2/C/D, W220 PhC/D

15.1.6 Maintenance works (M1, M2, M3 codes, see Chap.

04)
Maintenance work includes inspection and function checks of wea-
ring parts with or without changing process materials, parts or mo-
dules. It must be carried out in accordance with the intervals as set
out in Chap. 04.

Caution : Failure to carry out the maintenance work within the pres-
cribed intervals can lead to damage and inoperation of the turbo.
The safety instructions in the respective chapters must be observed
for all maintenance work.
The turbocharger must be removed to carry out the maintenance.
Damaged parts which could impair the correct functioning must be
replaced.
Screw fastenings must be tightened with a torque wrench, in accor-
dance with specifications given in Chap. 07.
If retightening is no longer possible, replace the screw faste-
nings or V-clamps.
Keep lubrication and process materials ready.

1. Bearing
2. Turbine
3. Compressor

Fig. 15-04

Caution : The operations on parts 1, 2 and 3 must be done by authorized engi-

neers from Wärtsilä.

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 W200 Ph2/C/D, W220 PhC/D Turbocharging and air cooling 15.

15.1.6.1 To clean the turbocharger, dismantle the silencer.

1 Remove the filter covers (item 1).
2 Withdraw the cover sheet-metals (items 3 & 4), bend up and
remove the felt segments (item 5).

Caution ! When cleaning, take care that the felt segments do not become wet.

3 Remove dirt from the felt segments with a soft brush or dry
compressed air.
4 Heavily soiled felt segments and filter ring should be re-
placed (see Spare Part Catalog, Chap. 158).

Note : Mount the extended cover sheet-metals (items 3 & 4) over the ribs
(item A).

Fig. 15-05

15.1.7 Filtering cover for turbocharger TPS52 and

TPS57
It can be washed with tepid water if necessary (dirtying) and should
be replaced as soon as a change appears (rip, burn, lost of elasticity,
ect...). Its lifetime depends on the ambient conditions (dusty, greasy
surroundings...).

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 15. Turbocharging and air cooling W200 Ph2/C/D, W220 PhC/D

15.1.8 V-clamps for turbochargers TPS52 and TPS57

15.1.8.1 Introduction
The turbocharger casings (turbine / compressor / main) and the
hoods (Exhaust / Inlet) have two types of assembly :

First type (see fig. 15-06)

The turbocharger, inlet and outlet sides, is assembled with clamps,
called "V-clamp".
Exhaust elbow
V-clamp

Air filter Compressor Turbine casing

v-clamp casing V- V-clamp
clamp

Fig. 15-06

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 W200 Ph2/C/D, W220 PhC/D Turbocharging and air cooling 15.

Second type (see fig. 15-07)

The turbocharger, inlet and outlet sides are assembled with screws.
Exhaust elbow
bolt connection

Air filter V-clamp Compressor casing Turbine casing

bolt connection
bolt connection

Fig. 15-07

15.1.8.2 Instructions
For all operations on the turbine side of the turbocharger, follow the
recommendations below :
· Completely dismantle the turbocharger from the engine.
· The turbine casing adjustement must be done from turbo-
charger in the vertical position.
· Pay special attention to the V-clamp level for the parts ad-
justement and tightening (see Chap. 07 for tightening).
· In case of dismantling, clean the different parts perfeclty,
never dismantle the nozzle ring. For the V-clamp, clean it
thoroughly with a steel brush before fitting.
· Lubricate the thread and the internal part of profile with
high temperature lubricating paste (ref. MGE000070 or
similar).
· Tighten the V-clamps (see Chap. 07). The V-clamps must
be tightened regularly, and in case there is not enough
clearance, V-clamp must be replaced. For the periodicity,
see Chap. 04.

Note : The V-clamps set must be replaced every 6000 running hours.

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 15. Turbocharging and air cooling W200 Ph2/C/D, W220 PhC/D

Warning : Never try to dismantle or adjust the turbocharger V-clamp on the en-
gine.
Never try to dismantle turbocharger turbine casing directly on the en-
gine.
Never try to dismantle the turbocharger from the engine without the
turbine casing and the exhaust elbow.

15.1.9 Cleaning the compressor (fig.15-08)

1 Apply penetrating lube oil to screw thread of V-clamp (item
2) and allow time to take effect.
2 Remove the silencer (item 1).
3 Remove the four bolts at the flange level of the compressor
casing.
4 Release V clamps (item 2) or screws slightly and turn the
compressor casing (item 3) upwards until the ring bolt can be
hooked on to the lifting equipment.
5 Attach lifting equippment to the compressor casing.

Caution : Take account of the weight of the casing to select a suitable rope.

6 Release V clamps or screws fully and remove the compres-

sor casing with wall insert (item 4) and O-ring (item 5).
7 Clean the compressor (item 6) and the diffuser (item 7) with
a nylon brush and pure water.
8 Set back the compressor casing in the right position.

Caution : Lubricate the threads and the internal part of profile with antiscuff or
similar high temperature paste ref. MGE000070.

9 Tighten the V clamps or screws (see Chap. 07 for tighte-

ning torque).

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 W200 Ph2/C/D, W220 PhC/D Turbocharging and air cooling 15.

10 Set back the silencer.

item A : Thread M10 (for 12V)
: Thread M12 (for 16V, 18V)
2 A 5 4 7

1 3 6

Fig. 15-08

15.1.10 Removing and installing the cartridge group

Caution : Take account of the weight of the cartridge group when selecting the
rope.

1 Follow the procedure "cleaning the compressor" (chap.

15.1.9).
2 Release and remove fixing screws (item A) of turbocharger
casing (fig. 15-09).
3 Check lifting equippment and for bearing casing.
4 Remove the cartridge group and gasket (item 7).
5 Plug lube oil channels for protection (item B).
6 Remove nozzle ring (item 4).
7 Measure axial and radial clearances (according to the
measurement record Chap. 06).

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 15. Turbocharging and air cooling W200 Ph2/C/D, W220 PhC/D

8 For the reassembly, fill in the procedure in reverse.

Fig. 15-09

Note : Check gasket rings for damage and replace them if you have any
doubt about their condition. Clean V-clamp (see Fig. 15-9, item 1) thor-
oughly with a steel brush before fitting.
Lubricate the thread and the internal part of the profile with Antiscuff
(or similar high temperature lubricating paste ref. MGE000070).

Caution : Do not damage or displace gasket rings (item B) in the turbocharger

foot during assembly (see Fig. 15-09).

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15.2 Charge air circuit

The engine charge air circuit is composed of 2 turbochargers (one
for each bank) feeding one common charge air cooler. The cooled
air is entering the cylinder after crossing the V part of the engine and
the multiducts.

1. Turbochargers
2. Charge air cooler (common)
3. Cut off valve

Fig. 15-10 / Figure is not contractual

15.2.1 Air cut-off valves (in option)

On the engine, after each turbocharger (compressor side), an air
cut-off valves (item 3 Fig. 15-10 and item 1 Fig. 15-11) is mounted
(*). In case of engine problems, a solenoide valve closes the air
cut-off valve in order to stop air inlet. The air cut-off valves is an air
flap type shutter.
(*) This device is used as a protection for the engine, in case the re-
moval engine shut down is not working.

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 15. Turbocharging and air cooling W200 Ph2/C/D, W220 PhC/D

15.2.1.1 Maintenance
F view

1 1
F view
F view

Fig. 15-11

After closing the air flap, use the dedicated tool to push the guillo-
tine plate in place (according to the attachement flap shaft).

Warning : Never put the fingers or hand inside the system.

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 W200 Ph2/C/D, W220 PhC/D Turbocharging and air cooling 15.

15.3 Charge air cooler maintenance

15.3.1 General maintenance
1 Condensation from the air is drained through a small drill
plug (item1) at the bottom between the charge air cooler and the
air manifold or the engine block. Make sure the draining pipes are
open by checking the air flow when running.

Caution : If water keeps on dripping or flowing from the draining pipe for a lon-
ger period (unless running all the time in conditions with very high hu-
midity), the cooler insert may be leaky and must be dismantled and
pressure tested.

Charge air cooler top view

Fig. 15-12 Detail of drill plug

2 At longer stops, the cooler should be either completely filled

or completely emptied, as a half-filled cooler increases the risk of
corrosion. If there is a risk of sinking water level in the system
when the engine is stopped, drain the cooler completely.

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 15. Turbocharging and air cooling W200 Ph2/C/D, W220 PhC/D

Open the air vent screw (item 9) to avoid vacuum when draining.

Fig. 15-13

15.3.2 Cleaning of the charge air cooler

Cleaning the water and air side heat exchange surfaces is imperative
for a long and trouble -free operation of the engine and must be
done at regular intervals according Chap. 04. If the air temperature
after cooler cannot be held, proceed to the charge air cooler inspec-
tion and cleaning if necessary (valves at full load).

Note : The maximum of Delta pressure between the two sides of the cooler
is 150 mbars.

1. Draining hole location air

2. Water pipes location
3. Hood
4. Protection grid
5. Visitor door
6. Fixing bolts 5
8. Header

1
3 6

8 2

Fig.15-14

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 W200 Ph2/C/D, W220 PhC/D Turbocharging and air cooling 15.

1 Drain the cooling water (see Chap. 19).

2 Remove the HT and LT cooling water pipes (item 2, Fig.
15-15).
3 Remove the protection grid around the charger cooler (item
4).
4 Remove the bolts at the connexion flanges at turbocharger
outlet level (item 6).
5 Open the visit door on the charge air cooler hood (item 5).
6 Apply the lifting tool SPC 8360011, see Spare Parts Catalogue,
chap. 836.
7 Remove the hood (item 3) (charge air pipe) of the charge air
cooler.

Fig. 15-15

8 Remove the cooler.

9 Clean the air and water sides of the cooler by immer-
sing it into a chemical cleaning bath for at least 24 hours. We re-
commend that the detergent is circulated for a better cleaning ef-
fect. After cleaning,applying a powerful water jet should flush the
cooler.
Recommended product :
Wärtsilä Biocleaner Combi Degreaser n° 003880062.

Note : If the water jet attacks the cooling tubes vertically, i.e. in parallel to the
fins, a pressure of 120 bars is suitable to be applied at a distance of two
meters from the fin surface.

10 Pressure test the cooler after cleaning.

11 Always check for corrosion when cleaning.

Caution : Wrong use of water jet may cause damage to the fins, which results in
an increased pressure drop over the air cooler and an decreased effi-
ciency.

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 15. Turbocharging and air cooling W200 Ph2/C/D, W220 PhC/D

12 Check the surface quality of the gaskets (item 1) between

the headers (item 2) and the cooler (item 3), fig.15-16.
13 Smear the gaskets with Perfect Seal paste, ref. 184751171.
14 Reassemble the cooler (item 3) in accordance with Fig.15-16.

1 3 1
2
2

Fig. 15-16

15 Mount the cooler on the engine. For that, it is mandatory to

replace all the screws.
16 Fill the water circuit.

Caution : Carefully follow the recommendations given in Chap. 07 for the posi-
tion of the screw and the torque to coupling.

17 Vent the cooler for a better venting. Start the pre-heating sys-
tem on and check the tightness when starting up (see Chap. 19).

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