Section 910

Turbocharger System

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Description
910.01 Air System of Engine

Plate
91001-121 Scavenge Air System
91002-84 Arrangement of Charging Air Pipe
91003-175 Exhaust Pipes and Receiver
91005-90 Air Cooler
91009-13 Cleaning of Air Cooler
 Air System of Engine
(Regarding the turbocharger, see the producer' s special instructions)
The engine is supplied with scavenge air
from one turbocharger mounted at the aft
end of the engine, or from one or two turbo-
charger mounted on the exhaust side of the
engine.
The engine exhaust gas drives the turbine
wheel of the turbocharger and, through a
common shaft, the turbine wheel drives the
compressor wheel.
The compressor draws air from the engine
room, through the air filters. From the com-
pressor outlet, the air passes through the
charging air pipe to the charging air cooler
(Plate 91005) where the air is cooled down.
The charging air pipe, with compensator, is
insulated and can be clad internally with a
sound-absorbing material.
The air cooler is designed to separate con-
densate from the air. See also ‘Charging Air
Cooler’ in this Chapter.
The air is pressed into the scavenge air
receiver through non-return valves mounted
in the air cooler housing after the water
mist catcher. The non-return valves (flap
valves), open by pressure from the turbo-
charger.
From the scavenge air receiver, the air
flows to the cylinder through the scavenge
air ports when the piston is in the bottom
position. When the exhaust valves open,
the exhaust gas is pressed into a common
exhaust gas receiver (Plate 91003), from
where the gas drives the turbine of the
turbocharger with an even and steady pres-
sure.
Scavenge Air Receiver
Plate 91001
The scavenge air receiver is a container
having a large volume. The receiver is bolt-
ed on to the cylinder frame.
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Plate
910.01-59
Scavenge air is collected in the receiver
after the air has passed through the cooler,
the water mist catcher and the non-return
valves.
The receiver and the cylinder frame com-
municate through circular openings.
The two auxiliary blowers are fitted to the
air cooler housing. The suction side of the
auxiliary blowers is connected to the space
before the non-return valves in the air
cooler housing. The discharge side is con-
nected to the scavenge air receiver via a
non-return valve, in or to prevent
reversed air flow. See also item, “Non-
return valves”, further on.
The scavenge air receiver is provided with
man-hole covers and also a safety valve
(Plate 91103).
Running with Auxiliary Blowers
During starting of the engine, or when the
engine is running at low load the turbo-
charger is not able to supply enough air for
the engine process. In these cases a pres-
sure switch will automatically start the
auxiliary blowers.
When the auxiliary blowers are operating,
they draw air from the engine room through
the turbocharger’s air filter and compressor
side.
This enables the turbocharger to maintain a
reasonable number of revolutions during
starting and at low load.
The air passes through the charging air
pipe, the charging air cooler, the water
mist catcher, to the suction side of the
blowers. From the blowers, the air is dis-
charged to the scavenge air receiver via
non-return valves.
The non-return valves fitted in the air cooler
housing are now closed due to partial
vacuum and gravitation acting on the valve
flaps.
 Air System of Engine
A lack of air supply will occur if the non-
return valves do not close.
Non-Return Valves
It is of the utmost importance that the non-
return valves of the auxiliary blowers al-
ways function correctly and move easily.
This can be checked by moving the valves
manually, e.g. in connection with the re-
gular scavenge port inspections.
The non-return valves protect the blowers
and engine during:
Starting the auxiliary blowers
Running with auxiliary blowers.
Starting the auxiliary blowers:
1) Owing to the relatively high starting
current, the blowers start in sequence,
with 6-10 seconds in between.
The non-return valve of the blower that
has not yet started must be in the
closed position to prevent the blower
from rotating backwards. Otherwise,
there is a risk of burning out the electric
motor when it starts.
2) If an auxiliary blower fails to start, the
non-return valve must be in the closed
position. Otherwise, the operating
blower will not be able to draw fresh air
in through the turbocharger and air
cooler. This is due to differences in the
air flow resistance.
Running with auxiliary blowers:
In the event of failure of an auxiliary blower
during running, the non-return valve must
close to ensure the continued supply of
fresh air to the engine.
See ‘Starting the auxiliary blowers’, ltem 2,
above.
HSD ENGINE CO., LTD.
Plate
910.02-59
Exhaust Gas Receiver
Plate 91003
From the exhaust valves, the exhaust gas
is led to the exhaust gas receiver where the
pulsatory pressure from the individual ex-
haust valves is equalized and led to the
turbocharger at a constant pressure.
The exhaust gas receiver is fastened to the
seating by flexible supports. Compensators
are inserted between the receiver and the
exhaust valves, and between the receiver
and the turbocharger.
Inside the exhaust gas receiver, a protec-
tive grating is mounted before the turbo-
charger.
The exhaust gas receiver and the exhaust
pipe are insulated.
The exhaust receiver may be provided with
by-pass flanges for:
emergency running without turbo-
charger
Improvement of fuel consumption
at part load via exhaust by-pass or
turbocharge cut-off system.
Turbo Compound system (TCS).
Charging Air Cooler
Plate 91005
The charging air cooler insert is of the block
type. It is mounted in a housing which is
welded up of steel plates.
The cooler housing is provided with inspec-
tion covers.
A water mist catcher is incorporated in the
air cooler housing. The water mist catcher
is built up of a number of lamellas which
separate the condensation water from the
scavenge air during the passage of the air
flow.
 Air System of Engine Plate
910.03-59

The separated water is collected in the

bottom of the cooler housing from where it
is removed by a drain system.

Caution !

It is important to check that the drain

functions correctly, as otherwise water
droplets may enter the cylinders.
See also Vol. I, OPERATlON, Chapter 706,
Cleaning of Turbochargers and Air
Coolers’.

An alarm device for high water level in the

drain system is installed.

EI. Panels for Auxiliary Blower

See special instructions supplied by the

engine builder.

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 Scavenge Air Receiver Plate
91001-0121

HSD ENGINE CO., LTD.

 Scavenge Air Receiver Plate
91001-0121

Item Item
Part Description Part Description
No. No.
017 Insulation cover
029 Insulation
030 Compensator
042 Nut
066 Screw
078 Charging air pipe
091 Insulation
101 Insulation cover
113 Screw
125 Cover
149 Screw
150 Screw
162 Distance pipe, L=35
186 Insulation
198 Screw
221 Plug screw
233 Screw
245 Nut
257 Distance pipe, L=60
269 Stud
270 Nut
282 Scavenge air receiver
294 Screw
316 O-ring
328 Cover
341 Stud
353 Clamp
365 Wing nut
389 Floor plates, complete
400 Locking plate
412 Screw
424 Locking plate

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 Arrangement of Charging Air Pipe Plate
91002-0084

HSD ENGINE CO., LTD.

 Arrangement of Charging Air Pipe Plate
91002-0084

Item Item
Part Description Part Description
No. No.
012 Nut
024 Screw
048 Butterfly valve
061 Screw
085 Nut
107 Guide pin
119 Nut
120 Screw
144 Screw
156 Lock washer
168 Stop plate
181 Spring pin
193 Support
203 Shaft
227 Butterfly valve
240 Screw
252 Locking device
264 Cover
276 Packing
288 Shaft
311 Valve flap
323 Valve housing
347 Cover
359 Packing
372 Screw
384 Support
406 Valve flap
418 Nut
443 Screw
455 Auxiliary blower
467 Screw
480 Screw
491 Locking plate

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 Exhaust Pipes and Receiver Plate
91003-0175

HSD ENGINE CO., LTD.

 Exhaust Pipes and Receiver Plate
91003-0175

Item Item
Part Description Part Description
No. No.
018 Seating special 641 Support
031 Insulation cover 653 Distance pipe, L=40
043 Wing nut 665 Insulation material
067 Screw 677 Insulation cover
079 Screw
080 Washer
092 Spring pin
102 Screw
114 Support
126 Nut
151 Exhaust receiver
163 Grid, complete
187 Packing
188 Packing
189 Packing
190 Packing
191 Packing
199 Locking plate
209 Washer
210 *) Screw
234 Manhole cover, complete
258 *) Screw
271 Compensator
283 Nut
295 Gas inlet
305 Insulation material
317 Insulation material
329 Nut
330 Insulation material
342 *) Screw
354 Distance pipe, L=30
366 *) Screw
378 Distance pipe, L=35
391 Frame
401 Wire gauze
413 Grid, complete
425 *) Screw
437 Cover plate
450 Support
486 Shim
498 Clamp
508 Spring plate
521 Spring pin
533 Screw
569 *) Screw
570 Compensator
*) These screws are special screws for
582 Nut
hot joints, they are marked with a “T”
594 Insulation material
and MUST NOT be used elsewhere
604 *) Screw
628 Distance pipe, L=70

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 Air Cooler Plate
91005-0090

HSD ENGINE CO., LTD.

 Air Cooler Plate
91005-0090

Item Item
Part Description Part Description
No. No.
019 Plate
020 Plate
044 Distance pipe, L=25
056 Screw
081 Screw
093 Nut
115 Screw
127 Flange
140 O-ring
164 Air cooler housing
188 Screw
211 Support
223 Spring pin
247 Flange
259 Cross member
260 Washer
272 Fitted stud
296 Screw
306 Distance pipe, L=30
331 Locking plate
343 Hinge
355 Cover
367 O-ring
380 O-ring
392 Flange
414 Water mist catcher
438 Cover
463 Cooler insert

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 Cleaning of Air Cooler Plate
91009-0013

HSD ENGINE CO., LTD.

 Cleaning of Air Cooler Plate
91009-0013

Item Item
Part Description Part Description
No. No.
010 Angle valve
022 Drain pipe
034 Butterfly valve "H"
058 Gasket
071 Stud
083 Nut
095 Nut
105 Stud
129 Main pipe
130 Main pipe
154 Angle valve
166 Staight valve "D"
178 Instruction plate
191 Butterfly valve "A"
201 Butterfly valve "E"
213 Guide pipe
225 Cleaning spray pipe
249 Drain pipe
250 Drain pipe
262 Orifice plate
274 Gasket
286 Stud
298 Guide pipe
333 Drain pipe
345 Drain pipe
357 Drain pipe
369 Drain box
370 Drain pipe

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