operators maintenance & overhaul
Contents
1. CAUTION Do not attempt to dismantle the turbocharger Service may only be performed by specially trained personnel Improper torques clearances or adjustments can ruin the unit 17 Table 3 Troubleshooting Engine Oil Consumption Excessive SYMPTOM OR ENGINE OIL TROUBLE CONSUMPTION EXCESSIVE POSSIBLE CAUSES AND REMEDIES Seal leakage at com Seal leakage at tur d haust Wrong type or vis pressor end of turbo bine end of turbo Ge Sd ies cosity of engine charger indicated charger indicated ae Ifuncti lubricating oil by oil in housing or by oil in housing or lead ner on wheel on wheel Service engine lube Perform troubleshoot Perform troubleshoot system in accordance ing procedures out ing procedures out with SS service lined in Table 6 lined in Table 7 manual Refer to engine service manual CAUTION Do not attempt to dismantle the turbocharger Service may only be performed by specially trained personnel Improper torques clearances or adjustments can ruin the unit 18 Table 4 Troubleshooting Noisy Turbocharger SYMPTOM OR TROUBLE TURBOCHARGER NOISY POSSIBLE CAUSES AND REMEDIES See Notes A and See Note H Foreign object or material in compres sor inlet ducting or NO compressor housing Dirty air cleaner element or inlet screen restricted in oil bath air cleaner Foreign object or material in co2. CLAMP LOCK PLATE MACHINE BOLT RETAINING RING MACHINE BOLT LOCK PLATE SEAL RING BACKPLATE ASSY 14 THEORY OF OPERATION During operation of a turbocharged engine exhaust gas from the engine exhaust manifold flows into the turbine See Figure 3 The exhaust gas pressure and the heat energy extracted from the gas cause the turbine wheel to rotate which in turn causes the compressor wheel to rotate The cooled and expanded exhaust gas leav ing the turbine wheel is directed by the turbine housing to the engine exhaust system which expels it to the atmos phere Rotation of the compressor wheel draws ambient air through the engine air clean er into the compressor housing where it is compressed and directed through duct ing to the engine intake manifold The increased density of the air deli vered to the engine cylinders permits a corresponding increase in the amount of fuel that can be delivered to the cylin ders while maintaining the air fuel ratio required for proper combustion Because engine power output changes with the amount of fuel burned the increase in the amount of fuel delivered results in an increase in engine power output Shaft rotation also activates the turbo charger oil seals At the oil slinger groove there is a difference in tip speed between the bottom of the groove and the larger diameter of the shaft Centrifugal force throws the oil outward to the walls of the center housing 011 i
3. Loose compressor to intake manifold duct connections Viscosity of oil in oil bath air clean er too high Leakage at engine intake manifold Replace air cleaner element or clean iniet screen in oil bath air cleaner Service air cleaner in accordance with manufacturer s service manual Tighten duct connec tions as required Refer to engine service manual See Notes D F and G See Notes D and F See Note K See Note H Restricted duct be tween air cleaner and turbocharger compressor Leakage at turbo charger mounting flange Turbocharger rotat ing assembly binding or dragging Leakage at engine exhaust manifold NO NO Check condition of gasket at turbo charger mounting flange and tight en loose bolts Remove restriction or replace damaged parts as necessary Perform trouble shooting procedures outlined in Table 5 Refer to engine service manual See Note Hai Engine malfunction fuel system com ponent valves valve timing rings pistons etc Restricted duct be tween compressor and engine intake manifold Restricted engine exhaust system after turbocharger Restricted engine intake or exhaust manifold NO YES YES YES YES Remove restriction Remove restriction or replace damaged or replace damaged parts as neces
4. a procedure tool device or work method not specifically recommended by Wisconsin Motors LLC is used you must satisfy yourself that it 1s safe for you and others You should also ensure that the engine will not be damaged or made unsafe by the procedures you choose IMPORTATNT the information specifications and illustrations in this book are on the basis of information available at the time it was written The specifications torques pressures of operation measurements adjustments illustrations and other items can change at any time These changes can effect the service given to the product Get the complete and most current information before you start any job Continental Distributors Dealers have the most current information which is available For a list of current Distributors Dealers refer to directory LIT101 7 or www wiscosninmotors com AA WARNING Most sub systems used in conjunction with Wisconsin Motors LLC industrial engines including but not lim ited to radiators hoses fans fuel tanks fuel lines or other fuel systems components hydraulic pumps and generators are not supplied by Wisconsin Motors LLC but are provided by the manufacturer of the end item in which the eingine is used Some of the dangers assoicatied with servicing such items are generally mentioned in this manual however the appropriate handbooks and safety instructions procided by the manufactureer of the end item should always be consulted prior to
5. carefully for cracks 4 Remove all carbon from combustion areas using scraper and wire brush 5 Clean the cylinder head thoroughly with a solvent or degreasing solution and blow it off with air pressure Inspect carefully for cracks VALVE GUIDES 1 Clean the valve stem guides removing lac quer or other deposits Do not use tools that remove metal 2 Check guides for wear by using a telescope gauge and 1 micrometer Replace all guides that are worn bell mouthed or have increased 0 038mm 0015 in diameter See Limits and Clearance Sec tion for maximum diameter permissible to deter mine actual amount it has increased Remove all valve guides when necessary by pressing them out from the combustion chamber side 3 Replace worn guides as required by pressing in new guides to the correct depth as given in the valve guide data TTP10148 page 42 Removing Valve Guides from Combustion Chamber Side CAUTION Wh n r placing guides do not ream since these are all pre reamed before b ing ferrox coated any further reaming will remove the coating SEE TTP10148 FOR ADDITIONAL INFORMATION VALVE SEAT INSERTS 1 The valve seat inserts are held in place by a shrink fit Inspect all valve inserts in the head and replace any that are loose cracked or other wise damaged Use puller for removing faulty insert 2 When required to replace with new insert clean and counterbore for 0 25mm 010 larger insert using
6. counterbore tool with cor rect fitting pilot When machining the counterbore be sure to go deep enough with the tool to clean up the bottom so that the insert will have full contact to carry away the heat Continental does not recommend installing new inserts having the same outside diameter as the one removed New insert installation must have a press fit Chill insert in container with dry ice for 20 minutes before assembling Insert may then be installed in the counterbore using a piloted driver and arbor press without the possibility of shearing the side walls This assures it being seated firmly on the bottom of the counterbore 3 Grind the intake and exhaust valve seats in the head in accordance with instructions in the Valve Guide Data TTP10148 page 42 Before removing the arbor indicate the seat Total indicator reading of the run out must not be more than 0 05mm 002 Use a pilot having a solid stem with a long taper as all valve seats must be ground concentric and square with either new or worn valve stem guide holes VALVE GUIDE DATA PN Fs mu 7 77 VA a Up E 2 D A lt 7 Lk k hhh gura SP P MV a a a PUn i LS T Model TMDT Valve Seat Angle 30 15 45 15 Diameter of Seat 39 77 33 50 1 566 1 319 C Diameter of Choke 35 0 29 0 1 38 1 14 Distance From Bottom 43 0 43 0 of Cylinder Head 1 69 1 69 E Length of Guide 60 4 60 4 2 38 2 38 F Ins
7. object impact In many cases metal piec es from the wheel become imbedded in the air cleaner element If the ele ment is not changed these metal pieces can be drawn into the replacement turbocharger and cause it to fail in the same manner as the original unit 23 Table 8 Troubleshooting Procedures Notes Continued With the air inlet and exhaust gas ducting removed from the turbocharger examine both the compressor and turbine wheels for blade damage Examine the outer blade tip edges for evidence of rubbing on housing surfaces Turn the rotating assembly by hand and feel for dragging or binding Push the rotating assembly sideways while rotating to feel for wheel rub If there is any indication of rubbing have the turbocharger serviced If the rotating assembly rotates freely and there is no evidence of binding or rubbing it can be assumed that the turbocharger is serviceable 24 TURBOCHARGER REMOVAL o oc Ro Disconnect oil drain line A at engine block and allow oil to drain Disconnect oil feed line B at engine block Remove air inlet ducting between turbocharger and air cleaner not shown Remove compressor outlet hose C at intake manifold Disconnect exhaust pipe D from turbine outlet While supporting the entire turbocharger unit disconnect turbine inlet pipe E at exhaust manifold and remove turbocharger assembly from the engine After the entire assembly is removed disconne
8. undertaking any work on sub systems attached to the engine to avoid any hazards inherent to these sub systems AA WARNING Read and observe all individual safety warnings as you use this manual to operate service or repair your engine Always exercise caution whenever working with an engine or any associated system Injuries may be caused by lack of care when working with or near moving parts hot parts pressurized systems electrical equipment or fuel systems Always wear eye and hearing protection when working on or near engines Improper attire such as loose clothing ties rings soft shoes or bare feet could be hazardous and should be avoided when servicing engines Use or service of the engine including the use of modified parts or materials not in accordance with manufacturer s specifications could damage your engine or cause personal injury AA WARNING Starting fluids or aids such as ether or gasoline must not be used in a diesel engine air intake system The use of these fluids will cause severe internal engine damage and or bodily injury AA WARNING Some equipment and materials used in the overhaul or maintenance of an engine such as machine tools electrical equipment compressed air solvents diesel gasoline or other fuels may be dangerous and can cause injury Always observe safety precautions associated with these items Cleaning Combustion Pocket Clean insert and combustion pocket Inspect
9. CONTINENTAL DIESEL ENGINE TMDT OPERATORS MAINTENANCE amp OVERHAUL MANUAL dd MOTORS LLC 2020 Fletcher Creek Drive Memphis Tennessee 38133 www wisconsinmotors com 2006 All Rights Reserved C USE IN CONJUNCTION WITH TMD OPERATORS MAINTENANCE AND OVERHAUL MANUAL TTP10148 IMPORTANT SAFETY NOTICE Proper repair is important to the safe and reliable operation of an engine This Service Manual outlines basic recommended procedures some of which require special tools devices or work methods Improper repair procedures can be dangerous and could result in injury or death READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND WARNINGS BEFORE PERFORMING REPAIRS ON THIS ENGINE Warning labels have also been put on the engines to provide instructions and identify specific hazards which if not heeded could cause bodily injury or death to you or other persons These labels identify hazards which may not be apparent to a trained mechanic There are many potential hazards for an untrained mechanic and there is no way to label the engine against all such hazards These warnings in the Service Manual and on the engine are identified by this symbol WARNING Operations that may result only in engine damage are identified in the Service Manual by the word CAUTION Wisconsin Motors LLC cannot anticipate every possible circumstance that might involve a potential hazard The warnings in this manual are therefore not all inclusive If
10. akage was caused by a restricted drain line the center housing may be full of sludged or coked oil and the unit may require overhaul Be sure the cause of the leakage has been corrected before installing another turbocharger Oil leakage into the compressor can also be caused by a restricted air intake system If the turbocharger cannot breathe freely oil pressure in the center housing can exceed air pressure in the compressor housing Oil will be forced past the seals into the compressor area In this case there is probably nothing mechani cally wrong with the turbocharger If oil de posits are heavy the unit should be removed and serviced Be sure to correct the air intake problem which may have been caused by a dirty air cleaner or debris or damage in the intake ducting Finally oil leakage into the compressor can be caused by frequent use of the engine as a brake for example descending a long grade with the transmission in low gear During this type of operation engine air demand can be high but energy input to the turbine is low and so turbocharger rotating speed is low The engine draws air through the compressor and AN WARNING creates a slight vacuum in the compressor housing sucking oil from the center housing past the shaft seal and into the compressor housing In this case nothing is wrong with either the engine or the turbocharger but frequent compressor wheel and housing clean up is recommended Fore
11. arch turbochargers are built for diesel and gasoline internal combus tion engines The turbocharger is com posed of an exhaust gas driven turbine and a radial air compressor on a common shaft The turbine and compressor wheels are mounted at opposite ends of the shaft which is enclosed and supported by a cen ter housing The turbine and compressor wheels are enclosed by cast housings at tached to the center housing The turbine is made up of a cast turbine wheel a wheel shroud and a housing that directs the flow of gas through the tur bine The inlet to the turbine is at the outer diameter of the housing Exhaust gas flows inward past the blades of the turbine wheel and exits at the center of the housing s diameter This means the turbine is a centripetal or radial inflow machine See Figure 1 The compressor is made up of a cast com pressor wheel a backplate and a housing that directs the flow of air through the compressor The inlet to the compressor is at the center of the housing s diame ter Air flows outward past the blades of the compressor wheel and exits at the outer diameter of the housing This means the compressor is a centrifugal or radial outflow machine The center housing supports the compressor and turbine wheel shaft in a pair of floating journal bearings See Figure 2 Passages drilled in the center housing direct oil from the engine lubricating system from the inlet port to oil grooves ma
12. chined in the center T NE EXHAUST TURMNE WHEEL sty AMBIENT AIR INLET COMPRESSOR WHEEL Figure 1 Turbine and Compressor Operation housing bearing bores These grooves align with holes in the journal bearings Oil flows through the holes in the bearings to lubricate and cool the bearing bores and shaft journals Oil is also directed from the inlet port through a passage in the backplate to the thrust bear ing Oil drains from the center housing by gravity Seals are installed at each end of the shaft between the journal bearing and the adjacent wheel to prevent lubricating oil from entering the compressor and turbine areas and to reduce the flow of gases from the compressor and turbine into the center housing Figure 2 shows a sectional view of a typical turbo charger 2 D gt JE IS 5 e R7 Figure 2 Sectional View of Typical Turbocharger NOMENCLATURE SELF LOCKING HEXAGON NUT COMPRESSOR HOUSING COMPRESSOR WHEEL PISTON RING THRUST COLLAR CLAMP LOCK PLATE MACHINE BOLT THRUST BEARING CENTER HOUSING ASSY JOURNAL BEARING WHEEL SHROUD PISTON RING 23 d A S K 4 GS t D r Geh Kei V aN 22 A N e S Sar NS f RS Ba AUR n A B N PM N SE SSS E Y 20 19 ITEM 14 15 16 17 18 19 20 21 22 23 d 2 18 17 16 NOMENCLATURE TURBINE WHEEL ASSY TURBINE HOUSING
13. ct all the above mentioned hoses and lines A B C E from the turbocharger Also remove oil drain line flange F Cover all turbocharger openings as soon as removal is complete TURBOCHARGER INSTALLATION 1 10 11 Remove all protective coverings from turbocharger openings CAUTION Do not allow any dirt or foreign matter to enter the openings during installation Using a new stainless steel gasket mount the turbine inlet pipe E on the turbine housing flange Use grade 8 bolts and torque 40 ft Ibs Also using a new stainless steel gasket mount the turbocharger assembly on the engine exhaust outlet flange Use grade 8 bolts and torque 40 ft Ibs Connect the compressor hose C between the compressor outlet and engine intake manifold Be sure to tighten clamps Connect the oil feed line B from the engine to the oil inlet port of the turbocharger center housing CAUTION Do not use any type of pipe thread sealant at the oil inlet port This material can clog internal oil passages Without allowing the engine to fire crank the engine until a steady stream of oil is seen draining from the turbocharger center housing oil drain Using a new gasket connect the oil drain line flange F to the turbocharger oil drain outlet Use 3 16 1 bolts and torque 25 ft Ib Connect oil drain line A between flange F and engine Make sure the line slopes downward the full length of its cour
14. e has dropped to zero damaging the turbocharger bearings ON ENGINE TROUBLESHOOTING The most common symptoms of turbocharger failure are related to engine performance Lack of power Excessive exhaust smoke Unusual noise Excessive oil or fuel consumption Of course any of these symptoms could be the result of an internal engine problem and might not involve the turbocharger at all Before the turbocharger is removed from the engine the turbocharger and its installation should be examined In many cases the brief troubleshooting procedure outlined in this section will help to determine whether the turbocharger is at fault in the complaint Also external or engine related causes of turbo charger failure may be found Such problems must be corrected before another turbocharger is installed or the new unit will fail just as the old one did The troubleshooting procedure contains these four steps 1 Examine the exterior of the turbo charger and its installation 2 Examine the turbine wheel and hous ing 3 Examine the compressor wheel and housing 4 Check the rotating assembly for noise or excessive play The following detailed explanations of these steps tell how to make the inspection and what the results mean Remember these steps are to be taken before the turbocharger is removed from the engine Any external or engine related faults found must be corrected before a re placement turbocharger is insta
15. ger must be overhauled Such damage destroys the wheel s balance and causes internal dam age to the seal bores and journal bear ings Be sure to find the source of the foreign object In many cases the ob ject has come out of the engine and there may be engine damage as well 3 EXAMINE COMPRESSOR WHEEL AND HOUSING A WARNING OPERATION OF THE TURBOCHARGER WITHOUT THE INLET DUCT AND AIR FILTER CONNECTED CAN RESULT IN PERSONAL INJURY AND DAMAGE TO EQUIPMENT FROM FOREIGN OBJECTS ENTERING THE TURBOCHARGER OPERATION OF A TURBOCHARGER WITH DAMAGED COMPONENTS MAY RESULT IN SERIOUS INJURY DUE TO VERY HIGH ROTATION SPEEDS SMALL IMBALANCES MAY CAUSE DISINTEGRA TION OF TURBOCHARGER UNIT Remove the ducting from the compressor inlet Figure 4 Using a flashlight check the com pressor for wheel to housing rub Figure 7 evidence of oil leakage Figure 8 or foreign object damage Figure 9 Figure 9 Compressor Foreign Object Damage Figure 7 Compressor Wheel to Housing Rub 14 Wh el to H u ing Rub If wheel rub is found and the housing attaching hardware is secure then the turbocharger is probably damaged inter nally and must be overhauled Oil L akage Oil leakage into the compressor can be caused by long periods of idling or a restricted oil drain line as discussed in Step 2 Check the items listed there Remember if oil de posits are heavy the unit should be removed and serviced If the le
16. he gasket materials Read Labels Setting Tappets See Notes 1 and 2 Form in Place 2 0mm 080 dia bead of Form in Place Gasket gasket material applied to oil pan and filler block as shown OIL PAN See Notes 1 and 2 Form in Place gasket material must extend from side seal recess to inner edge of seal re 9 0 mm 35 tainer as shown both sides Ss This area of Form in Place gasket must IMPORTANT After assembly of the intersect vertical cavities both sides 5 mm 30 bearing cap to the crankcase fill bearing cap side slots to capacity using RTV and _ syringe furnished in kit Sealant must Top View errant A E bleed out chamfer at crankcase split line Crankcase contact face engin The two curing inserts pipe cleaners in cluded in the kit must be used as follows Dip the curing insert into a container of Rear Bearing Cap and Filler Block clean water and insert full length into ar bearing cap side slot cavities filled with RTV material making certain the insert is centrally located in side slot Install in sert until approximately Ys protrudes from slot Cut off flush with oil pan rail See notes 1 and 2 Form in Place gasket material to plug holes Bottom View Min 6 0mm 236 deep from contact surface Oil Pan Contact Face Typical RTV Oil Pan Application for the Diese Overhead Valve Engine 6 TURBOCHARGER DESCRIPTION OPERATION AND TROUBLESHOOTING Garrett AiRese
17. ide Diameter Guide 8 717 8 692 8 717 8 692 3432 3422 3432 3422 G Distance Intake to Ex 47 65 haust 1 876 Outside Diameter of Insert 44 013 43 987 36 713 36 687 Free State 1 733 1 732 1 445 1 444 Inside Diameter of 43 910 43 885 36 610 36 585 Counterbore 1 729 1 728 1 441 1 440 Inserts Valve Seat Crankshaft Oil Seal in Block 3 Apply a light coat of cement national oil seal or EC 847 to the butting ends of the crankshaft oil seal halves Allow to become tacky before assembling Lightly coat the crankshaft con tact edge of the seal with graphite grease to prevent damage prior to use 4 Install Crankshaft 5 Apply alight coating of RTV Gasket Material to surface and graphite grease to the oil seal lip Carefully install the combination rear bear ing cap and filler block on to the dowels Insert the capscrews and torque to 150 162 Nm 110 120 Lb Ft Applying RTV to Rear Filler Block 6 After the rear cap is in place and torqued in ject RTV into each side seal slot D as shown in illustration Force the RTV into the channels until a steady flow comes out the corner chamfers Installing RTV in Rear Filler Block Channels NOTE Oil leakage will occur if any voids are left along these slots 7 Dip the curing insert in clean water Install insert until approximately Ss protrudes from slot Cut off flush with oil pan rail This insert ins
18. ign Object Damage OPERATION OF A TURBOCHARGER WITH DAMAGED COMPONENTS MAY RESULT IN SERIOUS INJURY DUE TO VERY HIGH ROTATION SPEEDS SMALL IMBALANCES MAY CAUSE DISINTEGRA TION OF TURBOCHARGER UNIT If the compressor wheel has been damaged by a foreign object the turbocharger must be overhauled as explained above In most cases the foreign object has come through the intake system Check for loose ducting or debris that may have been left in the system The object or pieces of the wheel may have entered the intake manifold and engine so be sure to check for engine damage before installing another turbocharger 4 CHECK ROTATING ASSEMBLY FOR NOISE OR EXCESSIVE PLAY If no damage is visible in the turbine and compressor areas spin the rotating assembly by hand It should spin freely with no drag or grinding noises Side load each wheel by hand while turn ing the assembly and check whether the wheels are contacting their housings If contact is seen the turbocharger is probably worn or damaged internally and must be overhauled Table 1 Troubleshooting Engine Lacks Power or Engine Exhaust Emits Black Smoke SYMPTOM OR TROUBLE ENGINE EXHAUST EMITS BLACK SMOKE ENGINE LACKS POWER OR POSSIBLE CAUSES AND REMEDIES See Notes B and C See Notes A and See Note A Dirty air cleaner element or inlet screen restricted in oit bath air cleaner
19. ith or replace damaged inlet screen in oil wetten Service manual parts as necessary bath air cleaner Tighten duct connec tions as required Restricted turbo charger oil drain line Worn or damaged com pressor wheel Plugged engine crank case breather Leakage at engine intake manifold Clean and remove restriction or re place oil drain line as required Clean and repair air intake system as necessary Overhaul turbocharger Refer to engine manufacturer s service manual Refer to engine manufacturers service manual Engine malfunction excessive piston blowby or high in ternal crankcase pressure Turbocharger bear ings bearing bores or shaft journals worn YES YES Have turbocharger Refer to engine serviced service manual CAUTION Do not attempt to dismantie the turbocharger Service may only be performed by specially trained personnel Improper torques clearances or adjustments can ruin the unit 21 Table 7 Troubleshooting Seal Leakage at Turbine End of Turbocharger SYMPTOM OR SEAL LEAKAGE AT TROUBLE TURBINE END OF TURBOCHARGER POSSIBLE CAUSES AND REMEDIES Restricted turbo Charger oil drain line Excessive pre oiling diss de sis crank case breather Siudged or coked center housing Clean and remove T Servie engine lu Oil will burn away Refer to engine restricti
20. lled 1 EXAMINE THE TURBOCHARGER EXTERIOR AND INSTALLATION Visually check for e Missing or loose nuts and bolts e Loose or damaged intake and exhaust ducting e Damaged oil supply and drain lines e Cracked or deteriorating turbocharger housings e External oil or coolant leakage Correct any installation problems If turbocharger parts are damaged the unit should be overhauled after completion of the remainder of this troubleshooting procedure 2 INSPECT TURBINE WHEEL AND HOUSING AN WARNING OPERATION OF THE TURBOCHARGER WITHOUT THE INLET DUCT AND AIR FILTER CONNECTED CAN RESULT IN PERSONAL INJURY AND DAMAGE EQUIPMENT FROM FOREIGN OBJECTS ENTERING THE TURBOCHARGER OPERATION OF A TURBOCHARGER WITH DAMAGED COMPONENTS MAY RESULT IN SERIOUS INJURY DUE TO VERY HIGH ROTATION SPEEDS SMALL IMBALANCES MAY CAUSE DISINTEGRA TION OF TURBOCHARGER UNIT TURBINE CAST IRON HOUSING TURHINE OUTLET COMPRESSOR ALUMINUM HOUSING WM x d KOSCH 222 TURBINE e INLET COMPRESSOR OUTLET N COMPRESSOR INLET Figure 4 Turbine and Compressor Inlet and Outlet Identification Figure 5 Turbine Wheel to Housing Rub Remove the ducting from the turbine outlet Figure 4 Using a flashlight check the turbine for wheel to housing rub Figure 5 evidence of oil leakage Figure 6 or foreign object damage Foreign object damage to the turbine is not usually visible th
21. mpres sor to intake mani fold ducting Foreign object in engine exhaust system Remove foreign ob ject Repair air intake system and have turbocharger serviced as necessary Remove foreign ob ject Repair air intake system and have turbocharger serviced as necessary Remove foreign ob ject Repair ex haust system and have turbocharger serviced as necessary Replace air cleaner element or clean inlet screen in oil bath air cleaner Turbocharger rotat ing assembly binding or dragging Carbon build up in turbine housing NO YES YES Clean housing or have Perform troubleshoot ing procedures out lined in Tabie 5 turbocharger serviced if required Check engine operating procedures Shown on Table 8 CAUTION Do not attempt to dismantle the turbocharger Service may only be performed by specially trained personnel Improper torques clearances or adjustments can ruin the unit 19 Table 5 Troubleshooting Turbocharger Rotating Assembly Binding or Dragging TURBOCHARGER ROTATING ASSEMBLY BINDING OR DRAG ING SYMPTOM OR TROUBLE POSSIBLE CAUSES AND REMEDIES See Note J Excessive dirt build up in compressor on housing or wheel Compressor wheel or turbine wheel rub bing on housing Damaged turbine wheel due to for eign object impact Damaged compressor wheel due
22. on or brication system Overhaul turbocharg No action required service manual replace oi drain line as required er Engine malfunction excessive piston blowby or high in ternal crankcase pressure Turbocharger bear ings bearing bores or shaft journals worn Have turbocharger Refer to engine serviced service manual CAUTION Do not attempt to dismantle the turbocharger Service may only be performed by specially trained personnel Improper torques clearances or adjustments can ruin the unit 22 Table 8 Troubleshooting Procedures Notes A Refer to the engine service manual for inspection requirements and replacement specifications B With engine stopped check duct clamping devices for tightness WARNING Starting fluid should never be used to start an engine Serious personal injury may result from improper use of such mixtures Explosion may result from improper use Use only for the diagnostic purpose outlined below Never apply starting fluid or similar mixtures to hot surfaces C With engine running at idle speed lightly spray intake duct connections with starting fluid Leaks at connections will be indicated by an increase in engine speed due to the starting fluid being drawn into the compressor and pumped into the engine combustion chambers D With engine running at idle speed check exhaust duct connections for leaks by applying lightweight oil or liquid soap to area
23. ow are required As engine power output increases and decreases the turbocharger responds to deliver the required amount of air To ensure maximum turbocharger service life observe the following precautions CAUTION 1 Do not operate the engine above idle before normal engine oil pressure has been established Applying full throttle im mediately upon initial start up can oper ate the turbocharger at excessive speed before the bearings receive adequate lub rication this is referred to as oil lag Operation of the turbocharger without a sufficient oil supply for a per iod as short as 5 seconds can cause bear ing failure 2 During exposure to temperatures low enough to congeal engine oil or following long periods of nonoperation crank the engine without starting until normal oil pressure has been established Then start the engine and run at idle speed for a few minutes before operating at higher rpm 3 After an engine oil change or any service that involves oil drainage pre oil the turbo charger by cranking the engine as above until normal oil pressure has been established Then start the engine and run at idle speed for a few minutes before operating at higher rpm 4 Before engine shut down operate the engine at low idle speed for a few minutes to allow the turbocharger to decelerate Shutting the engine down from a high oper ating speed can cause the turbocharger to continue to rotate after engine oil pres sur
24. rough the turbine outlet unless the damage is severe Figure 6 Turbine Oil Leakage Whe I to Housing Rub If wheel rub is found and the housing attaching hardware is secure then the turbocharger is probably damaged inter nally and must be overhauled Oll L If 011 deposits are found determine whether the oil has come from the engine exhaust or from the turbocharger center housing If the oil has come from the engine consult the engine service manual and correct the problem If oil deposits on the wheel are heavy the turbocharger should be removed and ser viced by an authorized service center AN WARNING Try to avoid long periods of idle Continued low pressure exhaust gasses and low turbo charger rotation speed may allow oil to seep past the shaft seal Make sure to properly maintain the engine lubrication system as outlined in the service manual Contaminated oil can restrict the turbocharger oil drain line and force oil past the shaft seal e Other possible causes of oil on the turbine e oil drain line damage e engine crankcase pressurization caused by restricted breather or excessive blowby e over filled crankcase Foreign Object Damage OPERATION OF THE TURBOCHARGER WITHOUT THE INLET DUCT AND AIR FILTER CONNECTED CAN RESULT IN PERSONAL INJURY AND DAMAGE TO EQUIPMENT FROM FOREIGN OBJECTS ENTERING THE TURBOCHARGER If foreign object damage to the turbine is visible the turbochar
25. s not allowed past the groove to the turbine or compres sor areas while the shaft is rotating TURBOCHARGER TURBINE COMPRESSOR EXHAUST ENGINE FILTERED AMBIENT INLET AIR conrsesseo ain ENGINE EXHAUST eas TURBINE EXHAUST GAS Figure 3 Turbocharger and Engine Operation PREVENTIVE MAINTENANCE Since no calibration or adjustment proced ures are possible on in service turbo chargers and since all lubrication re quirements are supplied by the engine on which the turbocharger is mounted no per iodic maintenance in the usual sense is required on a Garrett AiResearch turbo charger In addition due to the wide variation in operating modes and condi tions to which turbochargers are sub jected maintenance procedures based upon specific numbers of engine operating hours vehicle miles or calendar periods are not practicable Therefore preventive maintenance of a turbocharger consists primarily of ensuring that the integrity of the turbocharger and engine as a system is maintained and that the engine is not operated in a manner that is detrimental to the turbocharger CAUTION Do not attempt to dismantle the turbocharger Service may only be performed by specially trained personnel Improper tor ques clearances or adjustments can ruin the unit 10 PROPER OPERATING PROCEDURES Turbocharger operation is entirely automatic No special procedures beyond those listed bel
26. s of possible leakage and checking for bubbles Exhaust gas leakage between the engine block and the turbocharger inlet will also create a noise level change E With engine running at idle speed check for unusual noise and vibration If either condition is noted shut down the engine immediately to protect the turbocharger and engine from further damage With the engine stopped check the turbocharger shaft wheel assembly for damage as outlined in Note I below F With engine running a change in the noise level to a higher pitch can in dicate air leakage between the air cleaner and the engine or a gas leak between the engine block and the turbocharger inlet G Exhaust gas leakage may be indicated by heat discoloration in the area of the leak With the engine running noise level cycling from one level to another can indicate a plugged air cleaner a restriction in the air cleaner to com pressor duct or a heavy build up of dirt in the compressor housing or on the compressor wheel p Internal inspection of the center housing can be accomplished by removing the oil drain line and looking through the oil drain opening When a sludged or coked condition exists a heavy sludge build up will be seen on the shaft between the bearing journals and in the center housing from the oil drain opening back to the turbine end c 9 Thorough cleaning of the air intake system is essential following compres sor wheel damage due to foreign
27. sary parts as necessary Refer to engine service manual Refer to engine service manual Shown on Table 8 CAUTION Do not attempt to dismantle the turbocharger Service may only be performed by specially trained personnel Improper torques clearances or adjustments can ruin the unit 16 Table 2 Troubleshooting Engine Exhaust Emits Blue Smoke ENGINE EXHAUST SYMPTOM OR EMITS BLUE SMOKE TROUBLE POSSIBLE CAUSES AND REMEDIES See Notes A and H Dirty air cleaner element or inlet screen restricted in oil bath air cleaner Replace air cleaner element or clean inlet screen in oil bath air cleaner Plugged engine oil filter Service oil filter in accordance with engine service manual Shown on Table 8 See Note Ar Viscocity of oil in oil bath air clean er too high Service air cleaner accordance with service manual See Note Restricted duct De tweer air cleaner and turbocharger compressor Remove restriction or replace damaged parts as necessary See Notes B and C Loose compressor to intake manifoid duct connection Tighten duct connec tions as required Seal leakage at compressor end of turbocharger Perform troubleshoot ing procedures out lined in Table 6 See Note F Leakage at engine intake manifold Refer to engine service manual Engine malfunction rings pistons valves etc Refer to engine service manual
28. se and has no sharp bends or kinks Tighten clamps Using a new stainless steel gasket connect the exhaust pipe D to the turbocharger Connect ducting between air cleaner and turbocharger compressor inlet Check all connections for leaks SERVICE AND PARTS Available from your Authorized WISCONSIN Service Center AIAN California Proposition 65 The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WISCONSIN MOTORS LLC SALES OFFICE 2020 Fletcher Creek Drive Memphis Tennessee 38133 Phone 901 371 0353 or Toll Free 800 932 2858 www wisconsinmotors com JUN 2006 TTP 10069
29. to for eign object impact NO Clean and repair air intake system as necessary Clean compressor or have turbocharger serviced Worn bearings shaft journals or bearing bores Have turbocharger serviced Clean and repair en gine exhaust system as necessary Have turbocharger serviced Clean and repair air intake system as necessary Have turbocharger serviced See Note I Excessive carbon build up behind turbine wheel Sludged or coked center housing YES YES Coked oil or com Service engine lu bustion deposits brication system Have turbocharger Have turbocharger serviced serviced Shown on Table 8 CAUTION Do not attempt to dismantle the turbocharger Service may only be performed by specially trained personnel Improper torques clearances or adjustments can ruin the unit 20 Table 6 Troubleshooting Seal Leakage at Compressor End of Turbocharger SEAL LEAKAGE AT COMPRESSOR END OF TURBOCHARGER SYMPTOM OR TROUBLE POSSIBLE CAUSES AND REMEDIES Dirty air cleaner A D Restricted duct be element or inlet Viscosity of oil in tween air cleaner Loose compressor to screen restricted in oil bath air cleaner and turbocharger intake manifold duct oil bath air cleaner too high compressor connection Repiace air cleaner iction H Service air cleaner Remove restrictio element or clean in accordance w
30. ures complete cure of the RTV Install Curing Insert 8 Prior to installing oil pan apply a small bead of RTV material to the rear bearing cap and filler block as shown Fill Dowel holes with RTV BI Applying RTV to Rear Bearing Cap and Filler Block OIL PUMP The oil pump is assembled to the front of the cylinder block and front main bearing cap and is held in place by capscrews The extended portion of the body acts as a pilot fitting closely in a counterbore in the block and bearing cap maintaining a definite relation ship between the crankshaft and the oil pump assembly The pump is driven by a hardened key mounted in the crankshaft INSTALLING OIL When engine is completely assembled and fill ed with proper oil See Lubrication Sec set tap Before assembling the oil pan make sure the pets according to the following chart contact surfaces are flat and clean of any gasket material or oil MODEL INTAKE EXHAUST A form in place gasket material is used for seal TMDT TMD 0 36mm 0 46mm ing the engine oil pan to the crankcase The form 014 018 in place gasket should be applied to the oil pan and filler blocks as shown here Tighten the screws in accordance with limits prescribed in the torque chart to avoid looseness or overstressing NOTES 1 Parts must be assembled within 20 minutes after applying gasket material 2 Caution must be used in handling t
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