Test turbocharger

AR09.40-B-5910C

Test turbocharger

12.02.16



Check:

Danger!

Risk of injuries and damages when tilting and returning the cabin of the vehicle.

Make sure that the tilting and tilt-back area is free of objects and people. Tilt the cab to its final position. Tilt back the cabin to its correct service position lock-in.

AS60.80-B-0001-01A

1.1

Tilt the cab.

Trucks fitted with 457.922/928 engine

AR60.80-B-0010C

Danger!

Risk of injuries and damages when tilting and returning the engine hood.

Make sure that the tilting and tilt-back area is free of objects and people. Tilt hood and lock it with safety rod.

AS88.40-B-0001-01A

1.2

Tilt the engine hood.

Trucks fitted with 457.924/931 engine

AR88.40-B-1000B

1.3

Open engine compartment cover

Bus fitted with 457.907/908/909/915/916/925/926/927/929/932 engine

Refer to body maker instructions.

Danger!

Risk of damages and injuries when the starter is actuated and the gearbox is engaged.Risk of injuries when working while the engine is heated and operating.

Make sure the gearbox is in neutral.

Wear suitable clothing and pay attention to hot and moving engine parts.

AS00.00-B-0005-01A

2

Starting the engine

3

Check turbocharger (1) for noise or unusual vibration.

Uncommon noise and vibration can be caused by damaged turbocharger wheels and by lack of tightness in the intake system, air charge and exhaust.

4

Check tightness of line between air filter and turbocharger (1). Correct if necessary.

The admission of foreign material damages the turbocharger (1) wheels.

5

Check the charge air system piping for tightness, correct if necessary

Leaks may be verified by touch and by applying soap foam on the line, connections and hoses.

6

Check the exhaust system for tightness.

Leaks are detected by discoloration by heating of the leakage area.

7

Shut down the engine.

Wait until the engine cools down.

8

Remove the flange with the engine-brake mechanism.

Engine 457.924/925/926/929/931

AR14.15-B-6302D

Engine 457.907/908/909/915/916/922/927/928/932

AR14.15-B-6302E

9.1

Remove intake hose from turbocharger.

Engine 457.924/931

AR09.10-B-8030B

457.922/928 Engine

AR09.10-B-8030C

9.2

Remove turbocharger inlet pipe.

Engine 457.907/908/909/915/916/925/926/927/929/932

AR09.10-B-8250H

10

Check rotors for damages caused by foreign matter.

Foreign matter that enters the intake or exhaust system will damage turbocharger rotors. Small particles wear down blade leading edges. Larger, harder particles tend to tear or cut blades. Soft material such as paper, clean shop rag, or rubber pieces will bend blades backwards into the opposite rotor direction.

If damages occur due to the presence of strange material, it is necessary to clean completely the exhaust manifold and the air intake system.

In the case of damages, replace the turbocharger (1) 

Engine 457.922/924/928/931

AR09.40-B-6020E

Engine 457.907/908/909/915/916/925/926/927/929/932

AR09.40-B-6020F

11

Check the shaft (2) for free operation and the axial and radial clearance

The axle (2) of the turbocharger (1) must spin softly and uniformly. Usually, excessive radial and/or axial play produces attrition between the rotors and turbocharger housings, generating a noisy running.

In the case of damages, replace the turbocharger (1) 

AR09.40-B-5910-01B

Engine 457.922/924/928/931

AR09.40-B-6020E

Engine 457.907/908/909/915/916/925/926/927/929/932

AR09.40-B-6020F

12

Install flange with engine brake mechanism.

Engine 457.924/925/926/929/931

AR14.15-B-6302D

Engine 457.907/908/909/915/916/922/927/928/932

AR14.15-B-6302E

13.1

Install turbocharger intake hose.

Engine 457.924/931

AR09.10-B-8030B

457.922/928 Engine

AR09.10-B-8030C

13.2

Install turbocharger inlet pipe.

Engine 457.907/908/909/915/916/922/927/928/932

AR09.10-B-8250H