Do-it-yourself turbine repair on kamaz euro 2

For many car enthusiasts who love power and speed, the question of buying a car with a turbocharged engine is very important.

In turn, the task of the turbocharger is to supply a larger volume of air to the engine cylinders and, as a consequence, increase the power of the latter.

The only drawback of such a useful element is frequent failure, so every motorist should be able to make at least minimal repairs to the turbine.

Structurally, a turbocharger is a very simple mechanism that consists of several basic elements:

1. General body of the node and snail;
2. Plain bearing;
3. Thrust bearing;
4. Distance and thrust bushings.

The turbine housing is made of aluminum alloy and the shaft is made of steel.

Therefore, in the event of failure of these elements, the only correct solution is only replacement.

Most turbine damage can be easily diagnosed and repaired. At the same time, the work can be entrusted to professionals in their field, or you can do everything yourself.

In principle, there is nothing complicated about this (we will consider how to dismantle and repair a turbine in the article).

As the operating practice shows, there are two main reasons for breakdowns - poor-quality or untimely maintenance.

If, however, a technical inspection is made according to the plan, then the turbine will work for a long time and without any particular complaints from motorists.

So, today there are several main signs and reasons for turbine failure:

• 1. The appearance of blue smoke from the exhaust pipe at the time of increasing revs and its absence when the norm is reached. The main reason for such a malfunction is the ingress of oil into the combustion chamber due to a leak in the turbine.

Video (click to play).

• 2. Black smoke from the exhaust pipe - indicates the combustion of the fuel mixture in the intercooler or delivery line. The probable cause is damage or breakdown of the TKR (turbocharger) control system.

• 3. White smoke from the exhaust pipe indicates a clogged turbine oil drain line. In such a situation, only cleaning can save.

• 4. Excessive oil consumption up to one liter per thousand kilometers. In this case, you need to pay attention to the turbine and the presence of a leak. In addition, it is advisable to inspect the joints of the pipes.

• 5. The dynamics of acceleration is "dulled". This is a clear symptom of a lack of air in the engine. The reason is a malfunction or breakdown of the TKR control system (turbocharger).
• 6. The appearance of a whistle on a running engine. The likely cause is an air leak between the motor and the turbine.
• 7. Strange grinding noise during turbine operation often indicates the appearance of a crack or deformation in the housing of the unit. In most cases, with such symptoms, TCR does not "live" for a long time and further repair of the turbine may be ineffective.

• 8. Increased noise in the operation of the turbine can cause clogging of the oil line, change in the rotor clearances and rubbing of the latter against the turbocharger housing.
• 9. An increase in exhaust gas toxicity or fuel consumption often indicates problems with the supply of air to the TKR (turbocharger).

To repair the turbine with your own hands, it must be dismantled.

This is done in the following sequence:

• 1. Disconnect all piping that leads to the turbine. In this case, you should be extremely careful not to damage the node itself and the devices adjacent to it.

• 2. Remove the turbine and compressor volutes. The latter can be dismantled without problems, but the turbine volute is often attached very tightly.

Here, dismantling can be done in two ways - by the mallet method or by using the snail mounting bolts themselves (by gradually releasing them from all sides).

When performing work, you must be very careful not to damage the turbine wheel.

• 3. Once the work on dismantling the volutes is completed, you can check for any shaft play. If the latter is missing, then the problem is not with the shaft.

Again, slight lateral play is acceptable (but not more than one millimeter).

• 4. The next step is to remove the compressor wheels. Pliers come in handy to do this job. When dismantling, please note that the compressor shaft has a left-hand thread in most cases.

A special puller is useful to dismantle the compressor wheel.

• 5. Next, the sealing inserts are dismantled (they are located in the grooves of the rotor), as well as the thrust bearing (it is mounted on three bolts, so there are no problems with removal).

• 6. Now you can remove the liners from the end part - they are fastened with a retaining ring (sometimes you have to tinker when dismantling).

The plain bearings (compressor side) are secured with a circlip.

7. When performing dismantling work, it is necessary (regardless of the breakdown) to rinse and clean the main elements - cartridge, seals, rings and other components.

Once dismantling is complete, repairs can be made. To do this, there should be a special repair kit at hand, which contains everything you need - inserts, hardware, oil seals and rings.

Check the quality of the fixation of the nominal liners. If they are loose, then they need to be grooved and the shaft should be balanced.

In this case, it is advisable to clean the liners well and lubricate them with engine oil.

The retaining rings located inside the turbine must be installed in the cartridge. At the same time, make sure that they are in their place (in special grooves).

After that, you can mount the turbine liner, having previously lubricated it with engine oil. The liner is fixed with a retaining ring.

The next step is to mount the compressor liner, after which a well-lubricated liner can be inserted.

Next, put a plate on it and tighten it well with bolts (without fanaticism).

Install the dirt plate (secured with a retaining ring) and an oil scraper ring.

It remains only to return the snails to their place. That's all.

This article provides a general algorithm for disassembling and assembling a turbine. Of course, depending on the type of the latter, this algorithm will be partially changed, but the general course of work will be identical.

Well, if a serious breakdown is revealed, then it is better to immediately replace the old turbine with a new one.

In the absence of serious defects, the repair of the turbine takes no more than a few hours. But with the help of improvised tools and material prepared in advance, you can make a very high-quality and budgetary repair.

Taken from the classifieds site. Like a turbine with yamz 238 for kamaz 740.10

Firstly, the engine is clearly not a KamAZ 740.10 but probably a 7403.10 turbo or, in general, 740.11 - 240 E1, because a simple non-turbo motor with a degree of 17 and not 16 as on turbocharged early series will not walk for a long time (there, when supercharged, all 320 forces will climb out and the motor skiff).
secondly, the general turbine in the photo is similar to the TKR 102 or 100-ku from the YaMZ 238D, DE2.7511 engines - with a boost pressure from 0.8 to 1.25 bar, which depends on the settings of the motor itself.

when installing such a turbo on the 7403.10 engine, instead of twins, you can achieve power as on two native turbines, with a boost pressure of about 0.6 bar - NOT MORE because KAMAZ pistons “blow” less than even YAMZ 238D (where 0.8 bar). but after all, 7403.10 is designed for that.

One of the ways to increase the power of a diesel engine is a gas turbine pressurization system. Its main element is the turbocharger. It is installed on the discharge manifold and is driven by the energy of the exhaust gases. The use of a turbine at KamAZ gives an increase in engine power of about 25%. These trucks use two-row V-shaped power units. Therefore, 2 compressors are installed - each on its own block.

The ever-increasing requirements for environmental safety lead to the fact that manufacturers are forced to improve the design of engines and turbocharging systems. Therefore, when choosing a compressor and installing it yourself, you need to take into account the truck model and the brand of the power unit.

Today the most common turbine is KamAZ Euro-2. It is equipped with 4 brands of engines:

Compressors are produced by 3 Russian enterprises. Association "KamAZ" and JSC "Turbotekhnika" produce turbine units TKR-7. The characteristics of the product, made according to the two-console scheme, make it possible to use them on Euro-1 engines. The Belarusian enterprise in the city of Borisov manufactures an analogue of the TKR-7 turbine. The German concern Borg Warner Turbo Systems produces high quality products - with higher characteristics than Russian and Belarusian ones.

Cars equipped with Cummis power units are equipped with their own compressors. You need to know that in addition to these engines, the rest are equipped with twin turbines: right and left versions. KamAZ Euro-3 trucks are most often equipped with units of the German brand Schwitzer.

A malfunctioning turbocharger is characterized by one or more of the following distinguishing features:

• increased oil consumption;
• uncharacteristic sound of the operating unit;
• drop in the power of the power plant;
• the appearance of gray or blue smoke from the exhaust pipe.

You can check the turbine without dismantling it from its regular place. Primary diagnostics of the unit's performance includes:

• inspection of turbine and compressor rotor blades;
• checking the condition of the pipes;
• control of the presence of axial and radial play.

To check the condition of the blades, it is necessary to disconnect the exhaust pipe of the turbine and the discharge pipe of the compressor. Even small solid particles getting into the working cavities leads to the formation of scoring and chips on the body of the blades. At high rotational speeds (70-90 thousand rpm), this leads to an imbalance of the turbine unit, the appearance of an uneven load on the bearings, vibrations and, as a consequence, a drop in revolutions. Turbine malfunctions impair boosting parameters and reduce engine thrust.

The pipes must be free of oil traces. In some cases, oil fogging can be observed at the outlet of the compressor, however, the discharge pipe remains dry. Oily pipes and increased oil consumption can be caused by both turbine and engine malfunctions. Correct determination of the location of the defect will allow you to make the right decision to eliminate it.

The presence of backlash in the radial and axial directions is fraught with grazing of the shoulder blades against the walls of the cochlea. This can lead to complete destruction of the unit. Axial displacement of the rotor is not permitted. Backlash in the diametral plane of no more than 1 mm is possible. If the movement of the rotor is more than the norm, then the turbine unit must be dismantled for repair or replacement.

If, according to the results of diagnostics, it was not possible to find a malfunction, then it is necessary to check the tightness of the exhaust tract for the turbine and the pressure one for the compressor. A drop in vehicle power may be due to poor regulation or a malfunction of the fuel equipment. The condition of the air filter has a great influence on the airflow parameters.

Self-repair of KamAZ turbines is possible if spare parts are available. In most cases, impellers and bearings fail. It is impossible to restore, and even more so to balance, the shaft of the unit in a garage without special machines. In this case, the turbine can only be repaired in a specialized workshop.

Repair of a turbine unit involves:

• disassembly;
• identification of a damaged element or assembly;
• replacement of parts for workable ones;
• balancing the shaft with impellers;
• assembly of the unit;
• re-balancing of the assembled turbine.

It is impossible to eliminate the malfunction qualitatively without replacing the defective elements. Operating experience shows that a breakdown eliminated in a garage will soon remind of itself, only with more serious consequences.

In most cases, turbine defects are associated with the failure of an angular contact bearing.

This can happen both due to non-observance of the rules of operation of turbocharged engines (stopping the engine without idling), and due to a malfunction in the lubrication system.

With poor performance of filters and the presence of impurities in the oil, the gap between the oil screen and the seal disc decreases, which leads to a deterioration in the circulation of fluid in the system. This entails a breakdown of the oil wedge and, as a result, melting of the bearing. Therefore, when dismantling the turbine, the lubrication system of the turbocharger must be checked.

Some owners of trucks with non-turbocharged engines independently assemble units to increase engine power. The installation of a turbine on a simple KamAZ is associated with the manufacture of the foundation, because such a place is not provided for by the design. Most often, one unit is installed on both blocks. In most cases, turbochargers of Czech or German production are used.