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CONTINENTAL
DIESEL ENGINE TMDT
OPERATORS
MAINTENANCE
& OVERHAUL
MANUAL
WISCONSIN
MOTORS, LLC
2020 Fletcher Creek Drive, Memphis, Tennessee 38133
www.wisconsinmotors.com
(800) 932-2858
2006  All Rights Reserved
Wisconsin Motors, LLC
USE IN CONJUNCTIONWITH
TMD OPERATORS MAINTENANCE AND OVERHAUL
MANUALTTP10148
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 a procedure, tool, device or work method not
specifically recommended by Wisconsin Motors, LLC is used, you must satisfy yourself that it is 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 LIT1017 or www.wiscosninmotors.com.
1
! WARNING
Most sub-systems used in conjunction with Wisconsin Motors, LLC industrial engines including, but not limited 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 undertaking any work on sub-systems attached to the engine, to avoid any hazards inherent
to these sub-systems.
! 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.
! 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.
! 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.
2
CAUTION:
Whn r placing guides do not ream
sincetheseare all pre-reamed
beforeb ing ferrox
coated--any further reamingwill removethe
coating.
SEE TTP10148
FOR ADDITIONAL
Cleaning
INFORMATION
Combustion Pocket
Clean insert and combustion pocket. Inspect
carefully for cracks.
VALVESEAT INSERTS
4. Removeall carbon from combustion areas
using scraper and wire brush.
Thevalve seat inserts are held in place by a
shrinkfit.
5. Clean the cylinder head thoroughly with a
solvent or degreasingsolution and blow it off with
air pressure,Inspect carefully for cracks,
Inspect all valve inserts in the head and
replace any that are loose, cracked or otherwise damaged.Use puller for removingfaulty
insert.
VALVEGUIDES
1. Clean the valve stem guides, removing lac*
quer or other deposits. Do not use tools that
removemetal.
2. Checkguides for wear by using a telescope
gaugeand 1" micrometer. Replaceall guides that
are worn bell-mouthed or have increased 0.038mm
(.0015) in diameter. SeeLimits and ClearanceSection for maximum
diameter permissible to determine actual amountit has increased. Remove
all
valve guides when necessary by pressing them
out from the combustion chamberside.
3. Replaceworn guides as required by pressing
in newguides to the correct depth as given in the
valve guide data (TTP10148,
page42).
Whenrequired to replace with new insert,
clean and counterbore for 0.25mm(o010")
larger insert using cotmterboretool with correct fitting pilot.
Whenmachining the counterbore, be sure
to go deep enoughwith the tool to clean up
the bottom so that the insert will have full
contact to carry awaythe heat.
Continental does not recommend
installing
newinserts having the sameoutside diameter
as the one removed.
Newinsert installation musthave a press fit.
Chill insert in containerwith dry ice for 20 minutes
before assembling.
Insert maythen 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.
Removing Valve Guides from Combustion Chamber Side
3. Grindthe intake andexhaust
valveseatsin the head
in accordance
with instructions in the ValveGuideData
(TTP10148,page 42). Before removing the arbor,
indicatethe seat. Total indicator readingof the run-out
mustnot be morethan 0.05mm
(.002"). Use a pilot
havinga solid stemwith a longtaper, as all valveseats
mustbe groundconcentricandsquarewith either new
or wornvalve stemguideholes.
VALVE GUIDE
DATA
Model
TMDT
Intake
Exhaust
A
Valve Seat Angle
30 °15’
45° 15’
B
Diameter of Seat
39.77
(1.566)
33.50
(1.319)
C
Diameter of Choke
35.0
(1.38)
29.0
(1.14)
D
Distance (From Bottom
of Cylinder Head)
43.0
(1.69)
43.0
(1.69)
E
Length of Guide
60.4
(2.38)
60.4
(2.38)
F
Inside Diameter Guide
8.71718.692
(.34321.3422)
8.717/8.692
(.3432/.3422)
G
Distance Intake to Exhaust
47.65
(1.876)
Outside Diameter of Insert
(Free State)
44.013/43.987
(1.733/1.732)
36.713/36.687
(1.445/1.444)
Inside Diameter of
Counterbore
43.910/43.885
(1.729/1.728)
36.610/36.585
(1.441/1.440)
4
NOTE:
Oil leakagewill occur if any voids are left
along these slots.
7. Dip the curing insert in clean water. Install
insert until approximately 5/8" protrudes from slot.
Cut off flush with oil pan rail. This insert insures
complete cure of the RTV.
Crankshaft
Oil Sealin 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 becometacky before
assembling. Lightly coat the crankshaft contact edge of the seal with graphite grease to
prevent damageprior to use.
4. Install
Crankshaft.
5. Apply a light coating of RTVGasket Material to
surface "B" and graphite grease to the oil seal
lip. Carefully install the combination rear bearing cap and filler block on to the dowels. Insert
the capscrews and torque to 150-162 Nm
(110-120Lb. Ft.)
Install CuringInsert
8. Prior to installing oil pan, apply a small bead
of RTVmaterial to the rear bearing cap and filler
block as shown.
Dowelholes
with RTV
ApplyingRTVto RearFiller Block
6. After the rear cap is in. place and torqued, inject RTVinto each side seal slot "D" as shown
in illustration.
Force the RTVinto the channels
until
a steady flow comes out the corner
chamfers.
~/
ApplyingRTVto RearBearingCapandFiller 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 relationship between the crankshaft and the oil pump
assembly.
Installing RTVin RearFiller BlockChannels
The pumpis driven by a hardened key mounted
in the crankshaft.
INSTALLING
Whenengine is completely assembled and filled with proper oil, (See Lubrication Sec.) set tappets according to the following chart:
OIL PAN
Before assemblingthe oil pan makesure the
contactsurfacesare flat andclean of anygasket
materialor oil.
A form-in-placegasketmaterialis usedfor sealing the engineoil panto the crankcase.The form
-in-place gasketshouldbe applied to the oil pan
and filler blocksas shown
here.
MODEL
INTAKE
EXHAUST
TMDT/TMD
0.36ram
(.014")
0.46mm
(.018")
Tighten the screws in accordancewith limits
prescribed in the torque chart--to
avoid
loosenessor overstressing.
NOTES:
1. Parts must be assembled within 20
minutesafter applying gasket material.
2. Caution must be used in handling the
gasket materials. ReadLabels.
Setting
i
~.(See
~
Tappets
Notes
1
and
2)
J~’J
Form.in.Place
gasketmatedalappliedto oil panandfiller
block as shown
|| ~,
Ill
JJJ
I~1
~]
This area of Form-"
~n PI
¯ ace gasket must
intersect vertical cavities both sides ~
-~.~J
Top
¯ View
~
Crankcasecontact face~""RearBearingCapandFiller BI
(Seenotea1 and 2)/=~..~...---~(,0---)
Form-in-Place gasket matedal to plug
holes.
MIn 6.0ram(.236) deepfrom contact surface.
(See Notes 1 and 2) Form.in.Place
gasket material must extend from side
sea, recess to inner edgeof seal re-
#/ tMPORTANT-- After assembly ol the
~ %--r "~’’’-a¢’~
~’
J
bearing capto the crankcase,fill bearing
=~/.5ram(.30)/
cap side slots to capacity using RTVand
_
_ " ............ ,~
~"
~,.,,,~01
lOJJ
.syringe furnished in kit. Sealant must
/~__----~,~’]Dleed out chamferat crankcase split line.
~ "~ssli~[]IThe two curing inserts (pipe cleaners) in~ r
j cluded in the kit must be used as follows:
~
,f~
Dip the curing insert into a container of
~
J
J
J, ’~,~," II
lean water and insert full length into
bearing capside slot cavities filled with
RTVmaterial, makingcertain the insert
is centrally locatedin side slot. install insert until approximately %" protrudes
fromslot. Cut off flush with oil panrail.
or..~_t(~°~
~Bottom
View
Oil Pan Contact Face
Typical RTVOil Pan Application for the Diesel Overhead Valve Engine.
6
TURBOCHARGER DESCRIPTION,
OPERATION AND TROUBLESHOOTING
Garrett/AiResearch
turbochargers
are built
for dieseland gasolineinternalcombustion engines.The turbocharger
is composedof an exhaust-gas-driven
turbineand
a radialair compressor
on a commonshaft.
The turbineand compressorwheelsare
mountedat oppositeendsof the shaft,
whichis enclosedand supportedby a center housing.The turbineand compressor
wheelsare enclosedby casthousingsattachedto the centerhousing.
The turbineis madeup of a cast turbine
wheel,a wheelshroud,and a housingthat
directsthe flow of gas throughthe turbine.The inletto the turbineis at the
outerdiameterof the housing.Exhaust
gas flowsinward,past the bladesof the
turbinewheel,and exitsat the centerof
the housing’sdiameter.This meansthe
turbineis a centripetal,
or radialinflow, machine.(SeeFigure 1.)
The compressor
is madeup of a castcompressorwheel,a backplate,
and a housing
that directsthe flow of air throughthe
compressor.
The inletto the compressor
is at the centerof the housing’sdiameter. Air flowsoutward,past the blades
of the compressor
wheel,and exitsat the
outer diameterof the housing.This means
the compressor
is a centrifugal,
or
radial-outflow,
machine.
The center housing supports the compressor
andturbine wheelshaft in a pair of floating
journal bearings. (See Figure 2.) Passages
drilled in the center housingdirect oil (from
the enginelubricating system)from the inlet
port to oil groovesmachinedin the center
Figure1
Turbineand Compressor
Operation
housing bearing bores. Thesegrooves align
with holes in the journal bearings. Oil flows
throughthe holes in the bearingsto lubricate
and cool the bearing bores and shaft journals.
Oil is also directed from the inlet port through
a passagein the backplate to the thrust bearing. Oil drains from the center housingby
gravity.
Sealsare installed at eachend of the shaft
betweenthe journal bearing and the adjacent
wheelto prevent lubricating oil from entering
the compressorand turbine areas and to
reduce the flow of gases from the compressor
and turbine into the center housing. Figure 2
showsa sectional view of a typical turbocharger.
4
5
23
6 7
8
9
10
11
12 13
22 21 20 19 18 17 16
Figure 2. Sectional View of TypicaITurbocharger
ITEM
I.
2.
3.
4.
5.
6.
7.
8.
9.
I0.
Ii.
12.
13.
NOMENCLATURE
SELF-LOCKINGHEXAGON
NUT
COMPRESSOR
HOUSING
COMPRESSOR
WHEEL
PISTONRING
THRUSTCOLLAR
CLAMP
LOCKPLATE
MACHINEBOLT
THRUSTBEARING
CENTERHOUSINGASSY
JOURNALBEARING
WHEELSHROUD
PISTONRING
ITEM NOMENCLATURE
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
TURBINEWHEELASSY
TURBINEHOUSING
CLAMP
LOCKPLATE
MACHINEBOLT
RETAININGRING
MACHINEBOLT
LOCKPLATE
SEAL RING
BACKPLATE
ASSY
THEORY
OF OPERATION
TURBOCHARGER
During operation of a turbochargedengine,
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 causethe turbine wheel
to rotate which, in turn, causesthe compressor
wheelto rotate.
TURBINE
COMPRESSOR
EXHAUST
INLET
The cooledand expandedexhaustgas leaving the turbinewheelis directedby the
turbinehousingto the engineexhaust
system,whichexpelsit to the atmosphere.
Rotationof the compressor
wheeldraws
ambientair throughthe engineair cleaner into the compressorhousing,whereit
is compressed
and directedthroughducting to the engineintakemanifold.
The increaseddensityof the air deliveredto the enginecylinderspermitsa
corresponding
increasein the amountof
fuel thatcan be deliveredto the cylinders whilemaintaining
the air-fuelratio
requiredfor propercombustion.
Because
enginepoweroutputchangeswith the
amountof fuelburned,the increasein
the amountof fuel deliveredresultsin
an increasein enginepoweroutput.
Shaftrotationalsoactivatesthe turbochargeroil seals.At the oil slinger
groove,thereis a difference
in tip speed
betweenthe bottomof the grooveand the
largerdiameterof the shaft.Centrifugal
forcethrowsthe oil outwardto the walls
of the centerhousing.Oil is not allowed
past the groovetotheturbineor compressor areaswhilethe shaftis rotating.
ENGINE
6LOCK
~
FILTERED
AMBIENTINLET
AIR
iHiHi~cOMPRESSEO
AIR
[~ENGINE EXHAUSTGAS
EXHAUST
GAS
~TURBINE
Figure 3. Turbochargerand
Engine Operation
PREVENTIVE
MAINTENANCE
Since no calibrationor adjustmentprocedures are possibleon in-serviceturbochargers,and since all lubricationrequirementsare suppliedby the engine on
which the turbochargeris mounted,no periodic maintenancein the usual sense is
requiredon a Garrett/AiResearch
turbocharger. In addition, due to the wide
variationin operatingmodes and conditions to which turbochargersare subjected, maintenanceproceduresbased upon
specificnumbers of engine operating
hours, vehicle miles, or calendarperiods
are not practicable.
Therefore,preventivemaintenanceof a
turbochargerconsistsprimarily of
ensuringthat the integrityof the
turbochargerand engine as a system is
maintained,and that the engine is not
operatedin 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 torques, clearances, or adjustments can ruin the
unit.
lO
PROPER OPERATING
PROCEDURES
ON-ENGINE
TROUBLESHOOTING
The most commonsymptomsof turbocharger
failureare relatedto engineperformance:
Turbochargeroperation is entirely automatic.
No special proceduresbeyondthose listed
below are required. As engine poweroutput
increases and decreases, the turbocharger
respondsto deliver the required amountof air.
To ensure maximum
turbocharger service life,
observethe following precautions:
¯
¯
¯
¯
Lackof power
Excessiveexhaustsmoke
Unusualnoise
Excessiveoil or fuelconsumption.
Of course,any of thesesymptomscouldbe
the resultof an internalengineproblem,
and mightnot involvethe turbocharger
at
all.
CAUTION:
1. Do not operatethe engineabove idle
beforenormalengineoil pressurehas been
established.
Applyingfull throttleimmediatelyupon initialstart-upcan operate the turbocharger
at excessivespeed
beforethe bearingsreceiveadequatelubrication(thisis referredto as "oil
lag").Operationof the turbocharger
withouta sufficient
oil supplyfor a period as shortas 5 secondscan causebearing failure.
2. During exposure to temperatures low
enoughto congealengine oil, or following long
periods of nonoperationcrank the engine
without starting until normaloil pressurehas
beenestablished. Thenstart the engine and
run at idle speedfor a few minutesbefore
operating at higher rpm.
Before the turbocharger is removedfrom the
engine, the turbochargerandits installation
should be examined.In manycases, the brief
troubleshootingprocedureoutlined in this
section will help to determinewhetherthe
turbochargeris at fault in the complaint.Also,
external or engine-related causesof turbocharger failure maybe found. Suchproblems
must be corrected before another turbocharger
is installed, or the newunit will fail just as the
old onedid.
Thetroubleshooting procedure contains these
four steps:
1. Examinethe exteriorof the turbochargerand its installation.
3. After an engine oil changeor any service
that involves oil drainage,pre-oil the turbocharger by cranking the engine as aboveuntil
normaloil pressure has beenestablished.
Thenstart the engineand run at idle speedfor
a few minutes before operating at higher rpm.
2. Examinethe turbinewheeland housing.
3. Examinethe compressorwheel and
housing.
4. Beforeengineshut-down,operatethe
engineat low idlespeedfor a few minutes
to allowthe turbocharger
to decelerate.
Shuttingthe enginedown froma high operatingspeedcan causethe turbocharger
to
continueto rotateafterengineoil pressure has droppedto zero,damagingthe
turbocharger
bearings.
11
4. Check the rotatingassemblyfor
noiseor excessive
play.
TURBIN£
I~ASTIRONHOUSINg)
The following detailed explanations of these
steps tell how to makethe 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 replacement turbocharger is installed.
1. EXAMINE THE TURBOCHARGER
EXTERIOR AND INSTALLATION
Visually check for:
Missing or loose nuts and bolts
¯
¯
Loose or damaged intake and exhaust
ducting
¯
Damagedoil supply and drain lines
Cracked or deteriorating
turbocharger
¯
housings
¯
External oil or coolant leakage.
Figure 4. Turbine and Compressor Inlet
and Outlet Identification
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
/
WARNING
OPERATION OF THE TURBOCHARGER
WITHOUT THE INLET DUCT AND AIR
FILTER CONNECTEDCAN 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 DISINTEGRATION OF TURBOCHARGERUNIT.
Figure 5. Turbine Wheel-to-Housing Rub
Removethe 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 damageto the turbine
is not usually visible through the turbine outlet
unless the damageis severe.
12
Try to avoid long periods of idle. Continued
low pressure exhaust gasses and low turbocharger rotation speed mayallow oil to seep
past the shaft seal.
Makesure 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.
¯ Other possible causes of oil on the turbine:
¯ oil drain line damage
¯ engine crankcase pressurization caused
by restricted breather or excessive blowby
¯ over filled crankcase
Foreign
Object
/
Figure 6. Turbine Oil Leakage
Whe I-to-Housing
WARNING
OPERATION OF THE TURBOCHARGER
WITHOUT THE INLET DUCT AND AIR
FILTER CONNECTEDCAN RESULT IN
PERSONAL INJURY AND DAMAGE TO
EQUIPMENT FROM FOREIGN OBJECTS
ENTERING THE TURBOCHARGER.
Rub
If wheel rub is found, and the housing
attaching hardware is secure, then the
turbocharger is probably damaged internally and must be overhauled.
Oil
Damage
L akage
If oil deposits are found, determine
whether the oil has come from the engine
exhaust or from the turbocharger center
housing.
If the oil has comefrom 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 serviced by an authorized service center.
13
If foreign object damage to the turbine
is visible,
the turbocharger must be
overhauled. Such damage destroys the
wheel’s balance and causes internal
damage to the seal bores and journal bearings. Be sure to find the source of the
foreign object. In many cases, the object has come out of the engine, and
there may be engine damage as well.
3. EXAMINE COMPRESSORWHEEL
AND HOUSING.
/
WARNING
OPERATION OF THE TURBOCHARGER
WITHOUTTHE INLET DUCTAND AIR
FILTER CONNECTED
CAN RESULTIN
PERSONALINJURY AND DAMAGETO
EQUIPMENT FROM FOREIGN OBJECTS
ENTERING THE TURBOCHARGER.
OPERATION OF A TURBOCHARGER
WITH DAMAGEDCOMPONENTSMAY
RESULTIN SERIOUSINJURY. DUE TO
VERY HIGH ROTATIONSPEEDS, SMALL
IMBALANCESMAY CAUSEDISINTEGRATION OF TURBOCHARGER
UNIT.
Remove
the ducting from the compressorinlet
(Figure 4). Usinga flashlight, checkthe compressor for wheel-to-housingrub (Figure 7),
evidenceof oil leakage(Figure 8), or foreign
object damage
(Figure 9).
Figure 8. CompressorOil Leakage
Figure9.
Figure 7.
CompressorWheel-to-Housing Rub
14
CompressorForeign Object
Damage
Wh el-to-H
u ing Rub
creates a slight vacuumin the compressor
housing, sucking oil from the center housing
past the shaft seal and into the compressor
housing. In this case, nothing is wrongwith
either the engineor the turbocharger, but
frequent compressorwheel and housing cleanup is recommended.
If wheelrub is found,and the housing
attachinghardwareis secure,then the
turbocharger
is probablydamagedinternallyand mustbe overhauled.
Foreign Object Damage
011 L akage
/
Oil leakage into the compressorcan be
causedby long periods of idling or a restricted
oil drain line, as discussedin Step2. Check
the items listed there. Remember,
if oil deposits are heavy, the unit should be removed
and serviced. If the leakage wascausedby a
restricted drain line, the center housingmay
be full of sludgedor cokedoil andthe unit
mayrequire overhaul. Be sure the causeof the
leakagehas beencorrected before installing
another turbocharger.
WARNING
OPERATION OF A TURBOCHARGER
WITH DAMAGEDCOMPONENTSMAY
RESULTIN SERIOUSINJURY. DUE TO
VERY HIGH ROTATIONSPEEDS, SMALL
IMBALANCESMAY CAUSEDISINTEGRATION OF TURBOCHARGER
UNIT.
Oil leakage into the compressorcan also be
causedby a restricted air intake system.If the
turbochargercannotbreathe freely, oil pressure
in the center housing can exceedair pressure
in the compressorhousing. Oil will be forced
past the seals into the compressorarea. In
this case, there is probably nothing mechanically wrongwith the turbocharger.If oil deposits are heavy, the unit should be removed
and serviced. Besure to correct the air intake
problem, which mayhave been caused by a
dirty air cleaner or debris or damage
in the
intake ducting.
If the compressor
wheelhas been damaged
by a foreignobject,the turbocharger
mustbe overhauled,
as explainedabove.
In most cases,the foreignobjecthas
come throughthe intakesystem.Check
for looseducting,or debristhat may
have been left in the system.The object
or piecesof the wheelmay haveentered
the intakemanifoldand engine,so be
sure to checkfor enginedamagebefore
installinganotherturbocharger.
4. CHECK ROTATING ASSEMBLY
FOR NOISE OR EXCESSIVE PLAY .
If no damageis visiblein the turbine
and compressor
areas,spinthe rotating
assemblyby hand.It shouldspin freely
withno drag or grindingnoises.
Finally, oil leakageinto the compressorcan
be causedby frequent use of the engine as a
brake; for example,descendinga long grade
with the transmissionin low gear. During this
type of operation, engine air demandcan be
high, but energyinput to the turbine is low and
so turbochargerrotating speedis low. The
engine draws air through the compressorand
Side-loadeach wheelby handwhileturning the assemblyand checkwhetherthe
wheelsare contactingtheir housings.If
contactis seen,the turbocharger
is
probablyworn or damagedinternally
and
mustbe overhauled.
15
Table 1. Troubleshooting-Engine Lacks Power or Engine Exhaust Emits Black Smoke
SYMPTOMOR
TROUBLE
OR .~J
ENGINE LACKS
POWER
ENGINE EXHAUST
POSSIBLE CAUSESAND REMEDIES
~
(See Notes A and H*)
Dirty air cleaner
elementor inlet
screenrestricted in
oil bath air cleaner
I
YES
Viscosityof oil in
oil bathair cleaner too high
intake-manifold duct
connections
-- NO
I
YES
Replaceair cleaner
elementor clean
inlet screenin oil
bath air cleaner.
I
YES
Referto engine
service manual.
Referto engine
service manual.
(See Note K*)
Leakageat turbocharger mounting
flange
Turbochargerrotating assemblybinding
or dragging
!
YES
I
YES
Checkcondition of
gasket at turbocharger mounting
flangeandtigt~ten loose bolts.
Performtroubleshooting procedures
outlinedin Table5.
Leakageat engine
intake manifold
YES
Tighten duct connections as required.
(See Notes D and F*)
--NO~
NO-.~,,
YES
Serviceair cleaner
in accordance
with
manufacturer’s
service manual.
(See NotesD, F, and G*)
Leakageat engine
exhaust manifold
(See Notes B and C*)
(See Note A*)
(See Note H*)
NO~
Restricted duct be- |
tweenair cleaner
and turbocharger
NO.
compressor
YES
Remove
restriction
or replace damaged
parts as necessary.
(See Note H*)
[~
Restricted duct between compressor and
engine intake
~- N 0 ,--~,manifold.
J
I
YES
Remove
restriction
or replace damaged
parts as necessary.
Restricted engine
exhaust System
(after turbocharger)
-
NO~
Restricted engine
intake or exhaust
manifold
I
YES
I
YES
Remove
restriction
or replace damaged
parts as necessary.
Refer to engine
service manual.
Enginemalfunction
(fuel systemcomponent, valves,
valve timing, rings,
pistons,etc.)
~
YES
Refer to engine
service manual.
*Shownon Table 8
Servicemayonly be performed
byspecially trained
CAUTION:Donot attemptto dismantlethe turbocharger.
personnel.Improper
torques,clearances,or adjustments
canruin the unit.
16
Table 2. Troubleshooting-Engine Exhaust Emits Blue Smoke
SYMPTOM OR
TROUBLE
ENGINE EXHAUST
EMITS BLUE SMOKE
POSSIBLE CAUSES AND REMEDIES
~
(See Notes A and H*)
Dirty air cleaner
elementor inlet
screenrestricted in
oil bath air cleaner
(See Note,A*)
mNO
oil bathair cleaner tooofhigh
_~ Viscocity
oil in
(See Notes B and C*)
-NO
intake-manifold duct
connection
__~ Loose
compressor-to-
YES
(See Note F*)
-NO .-~=.
Leakageat engine
intake manifold.
YES
Replaceair cleaner
elementor clean
inlet screenin oil
bath air cleaner,
Serviceair cleaner
in accordance
with
service manual.
Tighten duct connections as required.
Referto engine
service manual.
(See Note H*)
Pluggedengine oil
filter
I
YES
Serviceoil filter
in accordance
with
engineservice
manual.
--NO~
Restricted duct betwee~air cleaner
and turbocharger
compressor
Seal leakage at
compressorend of
turbocharger
Enginemalfunction
(rings, pistons,
valves,etc.)
I
YES
I
YES
I
YES
Remove
restriction
or replace damaged
parts as necessary.
Performtroubleshooting procedures
outlined in Table6.
Refer to engine
service manual.
*Shownon Table 8
Servicemayonly be performed
by speciallytrained
CAUTION:Donot attemptto dismantlethe turbocharger.
personnel.Improper
torques,clearances,or adjustments
canruin the unit.
17
Table 3. Troubleshooting-Engine Oil ConsumptionExcessive
SYMPTOM OR
TROUBLE
ENGINE OIL
CONSUMPTION
EXCE~IVE
POSSIBLE CAUSESAND REMEDIES
Wrongtype or viscosity of engine
lubricatingoil
I
YES
Seal leakageat compressorendof tud:>ocharger (indicated
by oil in housingor
on wheel)
I
YES
Seal leekageat turbine end of turbocharger (indicated
by oil in housingor
on wheel)
I
YES
Performtroubleshooting proceduresoutlined in Table6.
Performtroubleshooting procedures
outlined in Table7.
Oil in engineexhaust
manifold(indicating
malfunctionof rings,
pistons,valves, etc.)
I
YES
,
Serviceengineiube
systemin accordance
with engineservice
manual.
Refer to engine
service manual.
CAUTION:Donot attemptto dismantlethe turbocharger.
Servicemayonly be performed
by specially trained
personnel.
Improper
torques,clearances,or adjustments
canruin the unit.
18
Table 4. Troubleshooting-Noisy Turbocharger
SYMPTOM OR
TROUBLE
TURBOCHARGER
NOISY
POSSIBLE CAUSESAND REMEDIES
(See Notes A and H*)
Dirty air cleaner
/
elementor inlet
screenrestricted in
oil bath air cleaner
(See Note H*)
N~
Foreign object or
material in compressor inlet ducting or
compressor housing
Foreign object or
material in compressot-to-intake-manifold ducting
Foreign object in
engine exhaust
system
t
NO-
YI~S
, .
LI
Replaceair cleaner
elementor clean
inlet screenin oil
bath air cleaner.
Remove
foreign object. Repairair intake
systemand have
turbochargerserviced
as necessary.
Carbonbuild-up in
turbine housing
Turbochargerrotating assemblybinding
or dragging
I
YES
I
YES
Clean housingor have
turbochargerserviced
if required.Check
engineoperating
procedures.
Remove
foreign object. Repairair intake
systemand have
turbochargerserviced
as necessary.
Remove
foreign ob)eEl. Repairexhaust systemand
haveturbocharger
servicedas necessary.
Performtroubleshooting procedures
outlined in Table5.
"Shownon Table 8
CAUTION:Donot attemptto dismantlethe turbocharger.
Servicemayonly beperformed
by speciallytrained
personnel.Improper
torques,clearances,or adjustments
canruin the unit.
19
Table 5. Troubleshooting-Turbocharger Rotating AssemblyBinding or Dragging
SYMPTOM OR
TROUBLE
TURBOCHARGER
ROTATING ASSEMBLY
BINDING OR DRAG-
POSSIBLE CAUSESAND REMEDIES
~
(See Note J*)
Damagedcompressor
wheeldue to foreign object impact
I
YES
NO-"~
Damagedturbine
wheeldue to foreign object impact
Compressorwheel or
turbine wheelrubbing on housing
I
YES
I
YES
I
YES
Cleanand repair engine exhaust system
as necessary.Have
turbochargerserviced.
Wornbearings, shaft
journals, or bearing
bores. Have
turbochargerserviced.
Cleanandrepair air
intake systemas
necessary.Clean
compressoror have
turbochargerserviced.
t
Cleanandrepair air
intake systemas
necessary.Have
turbochargerserviced
--NO~
Excessive
dirt buildup in compressor(on
housingor wheel)
~
NO.
(See Note I*)
I
Excessive carbon
build-up behind
turbine wheel
Cokedoil or combustiondeposits.
Haveturbocharger
serviced.
m NO
~1
Sludged or coked
center housing.
1
yl~$
Serviceenginelubrication system.
Haveturbocharger
serviced.
*Shownon Table 8
CAUTION: Do not attempt to dismantle the turbocharger. Service mayonly be performed by specially trained
personnel. Improper torques, clearances, or adjustments can ruin the unit.
2O
Table 6. Troubleshooting-Seal Leakage at CompressorEnd of Turbocharger
SYMPTOMOR
TROUBLE
SEAL LEAKAGEAT
COMPRESSOREND
OF TURBOCHARGER
POSSIBLE CAUSESAND REMEDIES
Dirty air cleaner
elementor inlet
screenrestricted in
oil bath air cleaner
oil bath air cleaner
too high
NO
I
YES
~
Restricted duct betweenair cleaner
and turbocharger
compressor
Loosecompressor-tointake-manifold duct
connection
I
YES
I
YES
Replaceair cleanel
elementor clean
inlet screenin oil
bath air cleaner.
Serviceair cleaner
in accordance
with
service manual.
Remove
restriction
or replace damaged
parts as necessary.
Leakageat engine
intake manifold
Restricted turbochargeroil drain
line
Pluggedengine crankcase breather
Worn or damagedcompressor wheel
Tighten duct connections as required.
I
YES
I
YES
I
YES
I
YES
Refer to engine
manufacturer’sservice
manual.
Clean and remove
restriction or replaceoil drain line
as required.
Refer to engine
manufacturer’sservice
manual.
Cleanand repair air
intake systemas
necessary. Overhaul
turbocharger.
Turbochargerbearings, bearingbores,
or shaft journals
worn
!
YES
Haveturbocharger
serviced.
t
NO.
Enginemalfunction
(excessivepiston
blowbyor high internal crankcase
pressure)
I
YES
Referto engine
service manual.
CAUTION:Donot attemptto dismantlethe turbocharger.
Servicemayonly be performed
by speciallytrained
personnel.
Improper
torques,clearances,or adjustments
canruin the unit.
21
Table 7. Troubleshooting-Seal
Leakage at Turbine End of Turbocharger
SYMPTOMOR
TROUBLE
SEAL LEAKAGE AT
TUR81NE END OF
TURBOCHARGER
POSSIBLE CAUSESAND REMEDIES
Pluggedengine crankcase breather
Restricted turbochargeroil drain
line
Sludged or coked
center housing
I
YE~
I
YES
I
YES
I
YES
Oil will burn away.
NOaction required.
Referto engine
service manual.
Turbochargerbearings, bearing bores,
or shaft journals
worn
Enginemalfunction
(excessivepiston
blowbyor high internal crankcase
pressure)
Excessivepre-oiling
I
--NO--~=,-
Cleanand remove
restriction or
replaceoil drain
line as required.
t
NO.
Servie enginelubrication system.
Overhaulturbochsrger.
I
YES
YES
Haveturbocharger
serviced.
Refer to engine
service manual.
CAUTION:Donot attemptto dismantlethe turbocharger.
Servicemayonly be performed
by specially trained
personnel.Improper
torques,clearances,or adjustments
canruin the unit.
22
Table 8. Troubleshooting ProceduresNotes
A. Refer to the engine service manualfor inspection requirementsand replacementspecifications.
B. With engine stopped,
check duct clamping devices for
/
tightness.
WARNING
"Starting fluid" shouldneverbe usedto start an engine.Seriouspersonalinjury mayresult from
improperuseof suchmixtures. Explosionmayresult from improperuse. Useonly for the diagnostic
purposeoutlined below.Neverapply"starting fluid" or similar mixturesto hot surfaces.
Ce
With enginerunningat idle speed,lightly sprayintake duct connectionswith "starting fluid."
Leaksat connectionswill be indicated by an increase in enginespeeddueto the starting fluid
being drawninto the compressorand pumpedinto the engine combustionchambers.
De
With enginerunning at idle speed, checkexhaustduct connectionsfor leaks by applying
lightweight oil or liquid soapto areas of possible leakageandcheckingfor bubbles. Exhaust
gas leakagebetweenthe engineblock and the turbochargerinlet will also create a noise level
change.
With engine running at idle speed, check for unusual noise and vibration.
If either conditionis noted, shut down the engine immediatelyto protect
the turbochargerand engine from further damage. With the engine stopped,
check the turbochargershaft wheel assemblyfor damage as outlinedin Note
I, below.
With engine running,a change in the noise level to a higher pitch can indicate air leakage between the air cleaner and the engine or a gas leak
between the engine block and the turbochargerinlet.
Exhaust gas leakage may be indicated by heat discolorationin the area of
the leak.
He
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-compressor duct, or a heavy build-up of dirt in the compressorhousing or on
the compressorwheel.
Internal inspectionof the center housing can be accomplishedby removing
the oil drain line and looking through the oil drain opening. When a
sludged or coked conditionexists, a heavy sludge build-upwill be seen on
the shaft between the bearing journalsand in the center housing from the
oil drain opening back to the turbine end.
Thorough cleaningof the air intake system is essential followingcompressor wheel damage due to foreign object impact. In many cases, metal pieces from the wheel become imbedded in the air cleaner element. If the element is not changed, these metal pieces can be drawn into the replacement
turbochargerand cause it to fail in the same manner as the original unit.
23
Table 8. Troubleshooting ProceduresNotes (Continued)
With the air inlet and exhaustgas ducting removedfrom the turbocharger, examine
both the compressorand turbine wheels for blade damage.Examinethe outer blade
tip edgesfor evidenceof rubbing on housingsurfaces.
Ko
Turn the rotating assemblyby handand feet for dragging or binding. Pushthe
rotating assemblysidewayswhile rotating to feel for wheelrub. If there is any
indication of rubbing havethe turbochargerserviced. If the rotating assembly
rotates freely andthere is no evidenceof binding or rubbing, it can be assumed
that
the turbochargeris serviceable.
E
D
24
TURBOCHARGER REMOVAL
1. Disconnectoil drain line (A) at engineblock andallow oil to drain.
2. Disconnectoil feed line (B) at engineblock.
3. Remove
air inlet ducting betweenturbocharger and air cleaner (not shown).
compressoroutlet hose (C) at intake manifold.
4. Remove
5. Disconnectexhaust pipe (D) from turbine outlet.
6. While supportingthe entire turbochargerunit, disconnectturbine inlet pipe (E)
exhaust manifold and removeturbocharger assemblyfrom the engine.
7. After the entire assemblyis removed,disconnect all the above-mentionedhoses
and lines (A,B,C,E) from the turbocharger. Also removeoil drain line flange (F).
8. Cover all turbocharger openings as soon as removalis complete.
TURBOCHARGERINSTALLATION
Remove
all protective coverings from turbocharger openings.
CAUTION:
Do not allow any dirt or foreign matter to enter the openingsduring
installation.
2. Usinga newstainless steel gasket, mountthe turbine inlet pipe (E) on the turbine
housingflange. Use3/8 grade8 bolts andtorque 40 ft. Ibs.
3. Also using a newstainless steel gasket, mountthe turbocharger assemblyon the
engineexhaustoutlet flange. Use3/8 grade8 bolts andtorque 40 ft. Ibs.
4. Connect the compressorhose (C) betweenthe compressoroutlet and engine
intake manifold. Be sure to tighten clamps.
5. Connectthe oil feed line (B) fromthe engineto the oil inlet port of the
turbocharger center housing.
CAUTION:
Donot use any type of pipe thread sealant at the oil inlet port. This
material can clog internal oil passages.
Withoutallowing the engineto fire, crankthe engineuntil a steady streamof oil is
seendraining from the turbochargercenter housingoil drain port.
Usinga newgasket, connectthe oil drain line flange (F) to the turbochargeroil
drain outlet. Use3/8-16x1 bolts andtorque25 ft. lb.
Connectoil drain line (A) betweenflange (F) and engine. Makesure the
slopes downward
the full length of its course and has no sharp bendsor kinks.
Tighten clamps.
Using a newstainless steel gasket, connect the exhaustpipe (D) to the
turbocharger.
10. Connectducting betweenair cleaner and turbocharger compressorinlet.
11. Checkall connectionsfor leaks.
SERVICE AND PARTS
Available from your Authorized
WISCONSIN
Service Center
!
WARNING
!
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
TTP10069