Terex PT80 Engine Manual

-� a Perkins® THE HEART OF EVERY GREAT MACHINE

Specifications 804C-33T Industrial Engine

For use with the Terex PT80 Perkins 804C-33T Engine

PT80 Engine Identification Late Type

The PT80 with the late type engine has a hydraulic charge pump mounted on the front timing case.

Hydraulic charge pump on engine.

PT80 Front Timing Case and Front Plate for late engines with front mounted hydraulic charge pump.

Front Timing Case and Front Plate for engines without front mounted hydraulic charge pump.

Texex PT80 Engine Parts contact: Email: EngineParts@HeavyEquipment RestorationParts.com Alternate email: EngineParts2@gmail.com Phone: 269 673 1638

Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair informati on.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word'' such as "DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

A WARNING The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Perkins is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Perkins dealers or Perkins distributors have the most current information available.

A WARNING When replacement parts are required for this product Perkins recommends using Perkins replacement parts.

Failure to heed this warning can lead to prema­ ture failures, product damage, personal injury or death.

SENR9833-02

Table of Contents Specifications Section Engine Design ............................. ........................ 4 Fuel Injection Lines .................. .... ... .... ................. 4 Fuel Injection Pump .. . ... ......................... .... ....... ... 4 Fuel Injectors ..... ........... ....... .... ... . ....... ................. 5 Fuel Transfer Pump ......... ........ ... . ... ..................... 6 Lifter Group ............. ... .... .... ....... ... .... .... .............. ... 6 Rocker Shaft ............. .... ... .... ............... ... .............. 7 Valve Mechanism Cover .......... ........................ .... 7 Cylinder Head Valves ....... ................ ....... ............. 8 Cylinder Head . ..................... .... ............ .......... ...... 9 Exhaust Manifold ..... ...................................... ...... 9 Camshaft ............................................................. 9 Engine Oil Relief Valve ........................................ 11 Engine Oil Pump .................................................. 11 Engine Oil Pressure ............................................. 12 Engine Oil Bypass Valve ...................................... 12 Engine Oil Pan ..................................................... 13 Water Temperature Regulator .............................. 14 Cylinder Block ...................................................... 14 Crankshaft ........................................................... 16 Crankshaft Seals ................................................. 17 Connecting Rod Bearing Journal ......................... 17 Main Bearing Journal ............................................ 17 Connecting Rod ................................................... 17 Piston and Rings .................................................. 18 Front Housing and Covers ................................... 20 Gear Group (Front) ............................................... 20 Flywheel ............................................................... 21 Crankshaft Pulley ................................................. 21 Belt Tension Chart ............................................... 22 Alternator and Regulator ...................................... 23 Electric Starting Motor ......................................... 23 Glow Plugs ........................................................... 24 Turbocharger......................................................27

Index Section

Index ..................................................................... 25

3 Table of Contents

SENR9833-02

Specifications Section

Specifications Section

When the camshaft is viewed from the flywheel end of the engine, the camshaft rotates in the following direction: ....................................... Counterclockwise i01955627

Engine Design

Note: The left side and the right side of the engine are viewed from the flywheel end. The No. 1 cylinder is the front cylinder. i01891782

Fuel Injection Lines 1

2

4

3

GQQG 0 A Illustration 1

• B

g01016767

Cylinder and valve location

(A) Inlet valve

(B} Exhaust valve

Bore ............................................. 94 mm (3.70 inch) Stroke ........................................ 120 mm (4.72 inch) Displacement ...................................... 3.3 L (203 in3) Cylinder arrangement ..................................... In-line Type of combustion Naturally aspirated engines ...... Indirect injection Turbocharged engines ................. Direct injection

Illustration 2

(1) Tighten the nuts for the fuel injection lines to the following torque ...... 27 to 32 N·m {20 to 24 lb ft)

Compression ratio Naturally aspirated engines ......................... 22:1 Turbocharged engines ................................. 19:1 Number of cylinders ................................................ 4 Valves per cylinder .................................................. 2 Valve lash Inlet valve ....................... 0.25 mm (0.0098 inch) Exhaust valve ................. 0.25 mm (0.0098 inch) Firing order ................................................. 1, 3, 4, 2 Fuel injection timing ....................................... 5 ° BTC When the crankshaft is viewed from the flywheel end of the engine, the crankshaft rotates in the following direction: ....................................... Counterclockwise

g00993243

i01906880

Fuel Injection Pump Note: The engine is equipped with an axial piston distributor injection pump that is mechanically governed. Parts that are inside of the fuel injection pump are only serviceable by an authorized dealer.

SENR9833-02

5 Specifications Section

Fuel Injectors

i02506427

Naturally Aspirated Engines

2 ------

Illustration 3

g00993641

(1) Tighten the overflow valve for the fuel injection pump to the following torque . ......... 22 to 31 N·m (1 6 to 23 lb ft) (2) Screw for adjusting the full load setting (3) Tighten the nut for the fuel injection pump gear to the following torque.

Naturally aspirated engines ............ 59 to 69 N·m (43 to 51 lb ft) Turbocharged engines .................... 83 to 98 N·m (62 to 72 lb ft) (4) Fuel shutoff solenoid (5) Bolt for attaching to the gear case cover (6) Delivery valves for the fuel

Illustration 4

901010241

(1) Tighten the body in the retaining nut to the following torque ...... 34 to 39 N·m (25 to 29 lb ft)

Note: The fuel injector should only be disassembled and assembled by personnel with the proper training.

(2) Tighten the fuel injector in the engine to the following torque. ..... 53 to 65 N·m (39 to 48 lb ft) Type of fuel injector ............................... single orifice Injection pressure Standard at assembly .......... 11.77 to 12.75 MPa (1707 to 1849 psi)

SENR9833-02

Specifications Section

Turbocharged Engines

i01907139

Fuel Transfer Pump

·� Illustration 5

g00993511

(1) Tighten the retaining nut to the following torque..................... 25 to 34 N·m {18 to 25 lb ft) Note: The fuel injector should only be disassembled and assembled by personnel with the proper training.

Tighten the clamp bolt that secures the fuel injector in the cylinder head to the following torque. ........................... 21 to 23 N·m {15 to 17 lb ft)

Illustration 6

(1) Fuel transfer pump (2) Torque for one fitting ... 6 to 8 N·m (53 to 71 lb in} {3) Fuel filter/water separator

Type of fuel injector ............................ multiple orifice Injection pressure

900993469

i01900860

Lifter Group

Standard at assembly .......... 18.14 to 19.12 MPa (2631 to 2773 psi)

Illustration 7

g00988934

Clearance between the lifter and the bore in the engine for the lifter Standard at assembly ........... 0.016 to 0.052 mm (0.0006 to 0.0020 inch}

SENR9833-02

7 Specifications Section

Repair limit ...................... 0.08 mm (0.0031 inch) A

i02509351

Rocker Shaft B

5

B

Part No.: 233-5501 Table 1

-

Required Tools

- -· --

Tool

Part Number

A

21825617

�-

B

� - -·

-

-

Part Description

Qty

Dial lndicator Group V Block

2

Illustration 9

901256133

(5) Pushrods Place the pushrod in Tooling (B). Use Tooling (A} in order to check all pushrods for runout. Replace the pushrod if the runout exceeds the following value. ..................................... 0.30 mm (0.0118 inch) i01892068

Valve Mechanism Cover

Illustration 8

g00984738

(1) Rocker shaft Diameter of the rocker shaft .................................. 18.980 to 19.000 mm (0.7472 to 0.7480 inch) (2) Rocker arm Inside diameter of the rocker arm bushings ........................... 19.010 to 19.030 mm (0.7484 to 0.7492 inch) Clearance between the rocker arm bushing and the rocker shaft ..................... 0.010 to 0.050 mm (0.0004 to 0.0020 inch) Maximum permissible clearance between the rocker arm bushing and the rocker shaft .............................. 0.070 mm (0.0028 inch) (3) Spring (4) Tighten the bolts evenly. Tighten the lo�g bolt first. Tighten the bolts to the following torque. ...................... 10 to 20 N·m (7 to 15 lb ft)

Illustration 1 0

900984870

(1) Tighten the bolts for the valve mechanism cover to the following torque .................... 10 to 13 N·m (7 to 10 lb ft)

8

SENR9833-02

Specifications Section

Cylinder Head Valves

i01892207

Valve depth of the exhaust valve below the cylinder head face Standard at assembly ................... 0.4 to 0.6 mm (0.016 to 0.024 inch) Service limit ........................ 1.0 mm (0.039 inch) (5) Inlet valve

5

Diameter of the inlet valve _stem ...................................... 7.940 to 7.955 mm (0.3126 to 0.3132 inch) Service limit diameter of the inlet valve stem ............................... 7.900 mm (0.3110 inch) Clearance of the inlet valve stem in the inlet valve guide ..................................... 0.065 to 0.095 mm (0.0026 to 0.0037 inch) Maximum allowable clearance of the inlet valve stem in the inlet valve guide ............... 0.150 mm (0.0059 inch) Valve depth of the inlet valve below the cylinder head face

Illustration 11

901010358

(1) Valve spring Free length of the valve springs ......... 48.85 mm (1.92 inch) Service limit for free length of the valve springs .............................. 47.60 mm (1.87 inch) Length of the valve springs under set force ....................................... 43 mm (1.69 inch) Set force of the valve springs ......... 176 to 196 N (40 to 44 lb) Service limit for set force of the valve springs ........................................... 147 N (33 lb)

Standard at assembly ................... 0.3 to 0.5 mm (0.012 to 0.020 inch) Service limit ........................ 1.0 mm (0.039 inch) (6) Angle of the exhaust valve face from the horizontal axis Valve face angle ............................... 30 degrees Valve seat angle ............................... 30 degrees (7) Angle of the inlet valve face from the horizontal axis Valve face angle ............................... 30 degrees Valve seat angle ... .......... ....... ........... 30 degrees

(2) Valve spring recess (3) Valve guides Projection of the valve guide above the valve spring recess ... 14 ± 0.1 mm (0.55 ± 0.004 inch)

D

(4) Exhaust valve Diameter of the exhaust valve stem ...................................... 7.920 to 7.940 mm (0.3118 to 0.3126 inch) Service limit diameter of the exhaust valve stem .............................. 7.850 mm (0.3091 inch) Clearance of the exhaust valve stem in the exhaust valve guide ............... 0.080 to 0.115 mm (0.0031 to 0.0045 inch) Maximum allowable clearance of the exhaust valve stem in the exhaust valve guide __ 0.200 mm (0.0079 inch)

Illustration 12

900985069

Bore in the cylinder head for the valve seats

Bore for the inlet valve seat A ....... _....................... _................ _...... 45 degrees B ....... 46 to 46.0025 mm (1.8110 to 1.8111 inch) C ...................... 2 ± 0.1 mm (0.079 ± 0.004 inch)

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SENR9833-02

9 Specifications Section

D ...................... 8 ± 0.1 mm (0.315 ± 0.004 inch)

Exhaust Manifold

Bore for the exhaust valve seat A B C D

i01892668

....................................................... 45 degrees .......... 37 to 37.0025 mm (1.457 to 1 .458 inch) ...................... 2 ± 0.1 mm (0.079 ± 0.004 inch) ...................... 8 ± 0.1 mm (0.315 ± 0.004 inch) i01892090

Cylinder Head

rront

0 12

08

0 4

O 5

O

0 9

13 O 17

1 llustration 15

900985166

(1) Bolt Tighten the exhaust manifold bolts to the following torque.

Illustration 13

900964896

Tighten the cylinder head bolts in the sequence that is shown to the following torque. ....... 113 to 123 N·m (83 to 91 lb ft)

Naturally aspirated engines ............ 15 to 22 N·m (11 to 16 lb ft) Turbocharged engines .................... 28 to 33 N·m (21 to 24 lb ft) Maximum warpage of the flange for the exhaust manifold .................................. 0.20 mm (0.008 inch) i02506460

Camshaft

Illustration 14

900984909

3

The permissible distortion of the cylinder head is given below.

Maximum at assembly .... 0.05 mm (0.0020 inch) Repair limit ...................... 0.20 mm (0.0079 inch)

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Illustration 16

900988290

(1) End play of a new camshaft ...... 0.10 ± 0.25 mm (0.0039 ± 0.0098 inch) Maximum permissible end play of a worn camshaft ................................ 0.30 mm (0.0118 inch)

10 Specifications Section

SENR9833-02

(2) Tighten the thrust plate bolts to the following torque . ...................... 10 to 13 N·m (7 to 10 lb ft) (3) The diameters of the camshaft journals are given in the following table.

Table 2

--- ·-

Diameters of Camshaft Journals -- ---·

I I

Camshaft Journals

(B) Camshaft lobe height (C) Base circle To determine the lobe lift, use the procedure that follows: 1. Measure the camshaft lobe height (B).

Standard Diameter

Service Limit

2. Measure the base circle (C).

No. 1,2

53.94 to 53.96 mm (2.123 to 2.124 inch)

53.90 mm (2.122 inch)

3. Subtract the base circle that is found in Step 2 from the camshaft lobe height that is found in Step 1. The difference is the camshaft lobe lift.

No. 3

52.94 to 52.96 mm (2.084 to 2.085 inch)

52.90 mm (2.083 inch)

. ..

-·

- . .

-�

If the camshaft lobe lift is less than the service limit, replace the camshaft.

4

A

B

Illustration 18

901014070

(4) Camshaft Deflection over the full length of the camshaft

C _____, Illustration 17

900987844

Maximum at assembly .... 0.02 mm (0.0008 inch) Repair limit ...................... 0.05 mm (0.0020 inch)

(A) Camshaft lobe lift Naturally aspirated engines Inlet lobe ....................... 6.722 mm (0.2646 inch) Exhaust lobe ................. 6.720 mm (0.2645 inch) Turbocharged engines Inlet lobe ....................... 6.682 mm (0.2631 inch) Exhaust lobe ................. 6.722 mm (0.2646 inch) The service limit for camshaft lobe lift is given below: Naturally aspirated engines Inlet lobe ....................... 6.222 mm (0.2450 inch) Exhaust lobe ................. 6.220 mm (0.2449 inch) Turbocharged engines Inlet lobe ....................... 6.182 mm (0.2434 inch) Exhaust lobe ................. 6.222 mm (0.2450 inch)

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SENR9833-02

11 Specifications Section

i01893227

Engine Oil Relief Valve

900987876

Illustration 19

(1) Tighten the engine oil relief valve to the following torque . .................... 44 to 54 N·m (33 to 40 lb ft) Opening pressure of engine oil relief valve ................................. 350 ± 50 kPa (50 ± 7 psi)

Illustration 20

901256201

(1) Clearance between the outer rotor and the body Standard ................................... 0.20 to 0.30 mm (0.0079 to 0.0118 inch) Service limit .................... 0.50 mm (0.01 97 inch)

Note: The engine oil relief valve is located on the left side of the cylinder block. i02509468

Engine Oil Pump

Table 3

[

a Tool�_N_u_pm_�_e_r_

A

Required Tools

1.

-_

�rt De�-cr-ip-t-ion_ a

Feeler Gauge _

� 1

-

I Qfy

___ 1

Type ............................. Gear-driven differential rotor Number of lobes

Inner rotor ......................................................... 4 Outer rotor ........................................................ 5

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Illustration 21

901256201

(2) Clearance between the outer rotor and the inner rotor Standard ................................... 0.13 to 0.15 mm (0.0051 to 0.0059 inch) Service limit .................... 0.20 mm (0.0079 inch)

12 Specifications Section

SENR9833-02

Standard ................................ 0.025 to 0.111 mm (0.0010 to 0.0044 inch) Service limit .................. 0.200 mm (0.0079 inch) i02502471

Engine Oil Pressure Table 4

_i _ _ _ [�. �- _ _ __ _ . Oi_l _P_ re__ s�s_u_re_c1_

___j _

Lm Pressure at�5�0 rpm

262 ± 48 kPa (38 ± 7 psi)

I Oil pressure at idle

200 ± 48 kPa (29 ± 7 psi)

(1) The oil temperature must be 70 ° to 90 °C (158 ° to 194 °F).

The minimum acceptable oil pressure at low idle .................................................. 152 kPa (22 psi) g01256204

Illustration 22

(3) Clearance between the rotors and the body

i01935709

Engine Oil Bypass Valve

Standard ................................... 0.04 to 0.09 mm {0.0016 to 0.0035 inch) Service limit .................... 0.15 mm (0.0059 inch)

(

0 5 4

Illustration 23

g00996150

(4) Diameter of main shaft (near body) ................................. 15.985 to 16.000 mm (0.6293 to 0.6299 inch) Clearance between the main shaft and the body Standard ............................... 0.032 to 0.074 mm (0.001 3 to 0.0029 inch) Service limit .................... 0.15 mm (0.0059 inch) (5) Diameter of main shaft (near b ushing) ............................ 13.957 to 13.975 mm (0.5495 to 0.5502 inch) Clearance between the main shaft and the bushing

Illustration 24

900987878

Engine oil bypass valve Tighten the engine oil bypass valve to the following torque. ..... 64 to 74 N·m (47 to 55 lb ft) Opening pressure of engine oil bypass valve ....................................... 1.1 MPa (160 psi) Note: The engine oil bypass valve is mounted on the inside of the engine oil pan along the left side oil pan rail.

SENR9833-02

13 Specifications Section

Engine Oil Pan

i02509965

Table 5

Required Tools Tool

Part Number

A

21826038

POWERPART Silicone Sealant

B

21826051

POWERPART Sealing , Compound

C

21820117

Part Description

Q ty

POWERPART Threadlock and Nutlock

Illustration 2 6

901020644

Note: Apply Tooling (C) in order to reuse the bolts for the oil pan. Apply Tooling (C) to the first 13 mm (0.5118 inch) of the thread.

(1) Tighten the oil pan bolts to the following torque. ...................... 10 to 13 N·m (7 to 10 lb ft)

Illustration 25

901256709

Apply tooling (A) or Tooling (B) to the flange of the oil pan. Refer to illustration 26.

Illustration 27

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901256710

(2) Tighten the oil pan drain plug to the following torque..................... 34 to 44 N·m (25 to 33 lb ft)

14 Specifications Section

SENR9833-02

i01893737

Water Temperature Regulator

900877006

Illustration 28

The water temperature regulator starts to open at the following temperature . .... 82° ± 1.5° C (180° ± 2.7 ° F) The water temperature regulator has a lift of more than B mm (0.3 inch) at the following temperature. ...................................... 95 °C (203 °F) i02510338

Cylinder Block

(1) Cylinder bore

B

Table 7

·;ances of Cylinder Bores __ tandard at Repair Service Assembly Limit(1J Limit<2J

l ln_s1de .

Table 6

Required Tools

·- ·

Tool

B C

-

� --

21826038

A

-

Part Number

-

-- -

Part Description

Qty

POWERPART Silicone Sealant

21826051

POWERPART Sealing Compound

27610013

POWERPART Rubber Plug Replacer

----

94.000 to 94.035 mm (3.7008 to 3.7022 inch)

94.200 mm (3_7087 inch)

94.700 mm (3.7283 inch)

Out of Round

0.010 mm (0.0004 inch)

N/A

N/A

Taper

0.015 mm (0.0006 inch)

N/A

N/A

Diameter

�-

900987933

lllustration 29

(1) Bore the cylinder to the specified oversize dimension if the repair limit has been reached.

(2) Install a cylinder liner or replace the cylinder block if the service limit has been reached.

Bore the cylinder to the oversize dimension if the cylinder has uneven wear. Refer to Table 8.

Table 8

I I

Oversize Bore

Cylinder Bore Size

0.250 mm (0.0100 inch)

94.250 to 94.285 mm (3 .7106 to 3.7120 inch)

94 . 5ooto 94_ 535 mm 0.-500 mm (o.019 7 ;nch) __ (3.7205 to-3.7218 _ _ _� _ _ inch) _ _ _ _ _

_

The permissible distortion of the contact surface of the gasket is given below.

Maximum at assembly .... 0.05 mm (0.0020 inch)

SENR9833-02

15 Specifications Section

Repair limit ...................... 0.20 mm (0.0079 inch) (2) Main bearing cap bolts Use the following procedure in order to install the main bearing cap bolts: 1. Apply engine oil to the bearings and install the bearings to the caps.

Note: Apply a small amount of Tooling (A) or Tooling (B) to the corners of the cylinder block for the rear main bearing cap. After the rear main bearing cap is installed, remove any excess sealant from the inside of the recess for the rear oil seal. Excess sealant prevents the correct seating of the rear oil seal.

2. Install the cap to the crankcase so that the rear face of the cap is even with the rear face of the crankcase.

3. Apply clean engine oil to the threads of the main bearing cap bolts.

T ighten the main bearing cap bolts to the following torque ..................... 98 to 108 N¡m (72 to 80 lb ft)

Illustration 31

g01007117

(6) Seal for the front and rear main bearing caps.

(7) The seals for the front and the rear main bearing caps have a curve at one end. T he curved side must be installed toward the side of the engine.

The curved end is inserted first into the hole.

Note: Use Tooling (C) in order to install the seal correctly.

(8) Before installing the seals, inject a small quantity of Tooling (A) or Tooling (B) in the holes for the seals.

111 ustrati on 30

901007113

(3) Rear main bearing cap (4) Main bearing caps should have a marking that indicates placement and orientation.

(5) Front main bearing cap

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Illustration 32

(9) Seal for the front main bearing cap.

901007175

16 Specifications Section

SENR9833-02

Standard at assembly ........... 0.100 to 0.264 mm (0.0039 to 0.0104 inch) Repair limit ..................... 0.300 mm (0.0118 inch) Crankshaft deflection Maximum at assembly .... 0.02 mm (0.0008 inch) Repair limit ...................... 0.05 mm (0.0020 inch) Clearance between crankshaft bearing and craflkshaft journal Standard at assembly ............ 0.050 to 0.110 mm (0.0020 to 0.0043 inch) Repair limit .................... 0.200 mm (0.0079 inch)

Illustration 33

g00988954

(10) Inside diameter of the lifter bore Standard at assembly ....... 14.000 to 14.018 mm (0.5512 to 0.5519 inch) Service limit ................ 14.100 mm (0.5551 inch)

Crankshaft

900994009

Illustration 35

i01894898

(A) Original width of the rear crankshaft journal ............................... 31.000 to 31.039 mm (1.2205 to 1.2220 inch} Table 9

·

I

- --- -- -- -------

900987940

(1) Crankshaft end play

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- ·-

:. Oversize Width Oversize Thrust [ .; for Front OR Washer Rear

Oversize Width for Front AND Rear

31.150 to 31.189 mm (1.2264 to 1.2279 inch)

31.300 to 31.339 mm (1 .2323 to 1.2338 inch)

0.30 mm (0.012 inch)

31.300 to 31.339 mm (1.2323 to 1.2338 inch)

31.450 to 31.489 mm (1.2382 to 1.2397 inch)

0.45 mm (0.018 inch)

31.450 to 31.489 mm (1.2382 to 1.2397 inch)

31.600 to 31.639 mm (1.2441 to 1.2456 inch)

0.15 mm (0.006 inch)

·-·----· ------ - - - - - - · -

Illustration 34

--- �- --

Width of Crankshaft Journal for Oversize Thrust Washers

. -----�-

----

- --

·�

..

Refer to Specifications, "Connecting Rod Bearing Journal" for information on the connecting rod bearing journals.

Refer to Specifications, "Main Bearing Journal" for information on the main bearing journals and the main bearings.

SENR9833-02

17 Specifications Section

i01059939

i01907583

Main Bearing Journal

Crankshaft Seals

Table 11

Diameter of Crankshaft Journal (Bearing Surface) For Main Bearings

2

Original Size Journal(1l

77.955 to 77.970 mm (3.0691 to 3.0697 inch)

Undersize Journal 0.25 mm (0.010 inch)

77.705 to 77.720 mm (3.0592 to 3.0598 inch)

Undersize Journal 0.50 mm (0.020 inch)

77.455 to 77.470 mm (3.0494 to 3.0500 inch)

Undersize Journal 0.75 mm (0.030 inch)<2l

77.205 to 77.220 mm (3.0396 to 3.0402 in�h)

---+---

900554030

Illustration 36

(1) Oil seal (2) Oil seal sleeve Inspect the contact surface between the oil seal and the crankshaft for wear. If the crankshaft is worn, replace the oil seal with an oil seal and a sleeve assembly.

l

(1) Regrind the main bearing journals to the next undersize dimension if the repair limit of 77.850 mm (3.0650 inch) is exceeded.

(2) Service limit 77.100 mm (3.0354 inch)

The clearance between a new main bearing and a new main bearing journal is the following value. ..... 0.050 to 0.110 mm (0.0020 to 0.0043 inch) i01895665

Connecting Rod

i01907581

Connecting Rod Bearing Journal Table 10

Diameter of Crankshaft Journal (Bearing Surface) For Connecting Rod Bearings

Original Size Journal(1) -

Undersize Journal 0.25 mm (0.010 inch)

---+

57.955 to 57.970 mm (2.2817 to 2.2823 inch) -

57.705 to 57.720 mm (2.2718 to 2.2724 inch)

Undersize Journal 0.50 mm (0.020 inch)

57.455 to 57.470 mm (2.2620 to 2.2626 inch)

Undersize Journal 0.75 mm (0.030 inch)

57.205 to 57.220 mm (2.2522 to 2.2528 inch)

(1) Regrind the connecting rod bearing journals to the next undersize dimension if the r epair limit of 57.800 mm (2.2756 inch) is exceeded.

The clearance between a new connecting rod bearing and a new connecting rod bearing journal is the following value. ..................... 0.030 to 0.090 mm {0.0012 to 0.0035 inch) Service limit for clearance between a connecting rod bearing and a connecting rod bearing journal ................................. 0.200 mm (0.0079 inch)

Illustration 37

900987949

Prior to assembly, apply engine oil to the bearing.

(1) Install the bearing cap to the connecting rod and tighten the cap nuts to the following torque. .................... 49 to 59 N¡m (36 to 44 lb ft) Inside diameter of the piston pin bearing

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18 Specifications Section

SENR9833-02

Nominal value ........................ 30 mm (1.18 inch) Standard at assembly ....... 30.020 to 30.045 mm (1.1819 to 1.1829 inch) Clearance between the piston pin and the piston pin bearing Standard at assembly ........... 0.020 to 0.051 mm (0.0008 to 0.0020 inch) Service limit .................. 0.080 mm (0.0031 inch) End play of the connecting rod that is attached to the crankshaft.

Standard at assembly ....... 29.994 to 30.000 mm (1.1809 to 1.1811 inch) Clearance between the piston pin and the bore Standard at assembly ........... 0.000 to 0.016 mm (0.0000 to 0.0006 inch) Service limit .................. 0.050 mm (0.0020 inch) Refer to table 13 for the outside diameters of the pistvns.

Table 13

---·. ---

Standard at assembly ............... 0.15 to 0.35 mm (0.0059 to 0.0138 inch) Service limit ...................... 0.50 mm (0.020 inch)

Table 12 . ..

Part Number

A

-

B

21825617

Part Description

Service Limit

Standard

93.955 to 93.985 mm (3.6990 to 3.7002 inch)

93.770 mm (3.6917 inch)

0.25 mm (0.0098 inch) oversize

94.205 to 94.235 mm (3.7089 to 3.7100 inch)

0.50 mm (0.0197 inch) oversize

94.455 to 94.485 mm (3.7187 to 3.7199 inch)

-

.

-

94.020 mm (3.7016 inch)

--

·- ·

94.270 mm (3.7114 inch) --

Maximum difference in weight of the piston per engine ........................................ 0.005 kg (0.0110 lb)

Required Tools Tool

Item

- -

i02510694

Piston and Rings

·-· ·

Standard at Assembly

Qty

Feeler Gauge

-

Dial Indicator Group

Illustration 39

901256908

Use Tooling (A) in order to measure the piston ring end gap.

Illustration 38

900996359

(1) Diameter of the piston pin Nominal value ........................ 30 mm (1.18 inch)

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Standard at assembly ............... 0.30 to 0.50 mm (0.0118 to 0.0197 inch) Service limit .................... 1.50 mm (0.0591 inch)

SENR9833-02

19 Specifications Section

Standard at Assembly Naturally aspirated engines .... -0.25 to 0.15 mm (-0.0098 to 0.0059 inch) Turbocharged engines .............. 0.05 to 0.45 mm (0.0020 to 0.0177 inch) Compressed thickness of cylinder head gasket ................. 1.2 ± 0.05 mm (0.05 ± 0.002 inch)

© 6

Illustration 40

901256909

Use Tooling (A) in order to measure the clearance between the piston groove and a new piston ring.

No. 1 ring Standard at assembly ................ 0.07 to 0.11 mm (0.0028 to 0.0043 inch) Repair limit .................... 0.200 mm (0.0079 inch)

900987977

Illustration 42

(3) "WEIGHT" mark (4) "MATCHING" mark

No. 2 ring Standard at assembly ........... 0.045 to 0.085 mm (0.0018 to 0.0033 inch) Repair limit .................... 0.150 mm (0.0059 inch) Oil ring

Note: Assemble the piston and the connecting rod with the "WEIGHT" mark on the piston and with the "MATCHING" mark on the rod on the same side.

Standard at assembly ........... 0.025 to 0.065 mm (0.0010 to 0.0026 inch) Repair limit .................... 0.150 mm (0.0059 inch)

8

9

Illustration 43

(7) Camshaft side Illustration 41

901256910

Use Tooling (B) in order to measure the protrusion of the piston (2).

(8) End gap of No. 1 compression ring (9) End gap of No. 2 compression ring (10) Side with the inlet valve (11) End gap of oil ring

11

900987981

20 Specifications Section

SENR9833-02

Apply engine oil to the piston rings. Refer to Illustration 43 for the assembled configuration of the ends of the piston rings.

Gear Group (Front)

i02296835

Note: Install the piston with the "O" mark toward the front of the engine.

Front Housing and Covers

111 ustration 44

i02506518

g00987995

(1) Tighten the bolts that fasten the front plate to the cylinder block to the following torque . ...................... 10 to 13 N·m (7 to 10 lb ft) (2) Remove the excess gasket with a cutter.

Illustration 46

900988013

(1) Camshaft gear (2) Idler gear End play of idler gear Standard at assembly ............... 0.05 to 0.20 mm (0.0020 to 0.0079 inch) Service limit .................... 0.35 mm (0.0138 inch) Clearance between idler gear bushing and shaft Standard at assembly ........... 0.009 to 0.050 mm (0.0004 to 0.0020 inch) Service limit .................. 0.100 mm (0.0039 inch) (3) Fuel Injection pump gear Tighten the bolts for the fuel injection pump gear to the following torque.

Naturally aspirated engines ............ 59 to 69 N·m (43 to 51 lb ft) Turbocharged engines .................... 83 to 98 N·m (62 to 72 lb ft)

(3) Tighten the bolts that fasten the timing gear case to the front plate to the following torque ..................... 17 to 20 N·m (12 to 15 lb ft)

{4) Crankshaft gear (5) Oil pump gear (6) Tighten the thrust plate bolts for the idler gear to the following torque . ....................... 29 to 39 N·m (21 to 29 lb ft)

SENR9833-02

21 Specifications Section

(7) Tighten the locknut for the oil pump gear to the following torque...... 28 to 38 N·m (21 to 28 lb ft) Backlash for gears Helical gears at assembly ......... 0.03 to 0.18 mm (0.0012 to 0.0071 inch) Spur gears at assembly ................ .03 to .20 mm (0.0012 to 0.0079 inch) Service Limit ................... 0.25 mm (0.0098 inch)

i01896629

Flywheel Flatness of friction surface of the flywheel Maximum at assembly .... 0.15 mm (0.0059 inch) Repair limit ........................ 0.50 mm (0.020 inch) Face and bore runout's of flywheel

Engines that have a Balancer

Maximum at assembly .... 0.15 mm (0.0059 inch) Repair limit ........................ 0.50 mm (0.020 inch)

-C1)I

.J

=il�

1

I I

I I

901152815

Illustration 4 7

1. Measure the balancer shaft. Refer to illustration 47.

2. For information on the diameter of the balancer shaft, refer to table 14.

111 ustratio n 4 B

(1) Tighten the bolts for the flywheel to the following

torque. .................... 79 to 88 N·m (58 to 65 lb ft)

Table 14

Balancer Shaft

:

Shaft diameter 53.940 to 53.960 mm (2.1236 to 2.1244 inch) Clearance between balancer shaft and the bushing 0.04 to 0.09 mm (0.0016 to 0.0035 inch)

-1 Service limit 53.900 mm

900988073

i02510696

Crankshaft Pulley

(2.1220 inch)

Service limit 0.15 mm (0.0059 inch)

Table 15

Tool

Backlash for the balancer gears Backlash between left hand gear and the right hand gear ................................. 0.07 to 0.14 mm (0.0028 ± 0.0055 inch) Service Limit ................... 0.25 mm (0.0098 inch) Backlash between right hand gear and the crankshaft gear ......................... 0.03 to 0.17 mm (0.0012 to 0.0067 inch) Service Limit ................... 0.25 mm (0.0098 inch)

A

Required Tools ·- ,- rt � Pa Number Part Description 21826038

POWERPART Silicone , Sealant .

I; Qty 1

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22 Specifications Section

SENR9833-02

g00988100

Illustration 49

Note: Apply Tooling (A) to the threads of the crankshaft before the pulley nut is installed.

(1) Tighten the nut that fastens the crankshaft pulley to the crankshaft to the following torque. . ........... 480 to 500 N ¡m (354 to 369 lb ft) (2) Crankshaft pulley

3

Illustration 50

g00988022

(3) Maximum depth for the top of the V-belt in the groove ................................... 1.6 mm (0.06 inch)

Belt Tension Chart

i02506524

Note: Do not use the belt tension chart for belts with tensioners that are spring loaded.

SENR9833-02

23 Specifications Section

Table 16

Belt Tension Chart Belt Type

Type B

I _ __

Deflection

10 t o 1 2 mm (0.4 to 0.6 inch) _ _ _ _ _

Alternator and Regulator

i02535554

- - A_ P_P _lie� Force for Specifi�d Deflec�io� ---" _ 1 .

_____ 98 N (22 lb) -· -

_Electric Starting Motor

-�

i025D6531

Note: Apply a suitable Load to the battery in order to get the maximum alternator output.

Illustration 52

gD1D24163

The starting motor

(1) Electric starting motor (2) Tighten the nut on the starting motor terminal to the following torque. ....................... 18 to 25 N ·m (13.3 to 18.4 lb ft) Illustration 51

901268996

(1) Alternator and regulator Voltage ...................................................... 13.5 V Output current at 1500 rpm ..... 20 amp or higher Output current at 3000 rpm ..... 50 amp or higher Output current at 5000 rpm ..... 60 amp or higher Adjusting voltage of the regulator at 5000 rpm with a load of 5 amp or lower .................... 14.2 V to 14.8 V

(3) Tighten the starting motor terminal to the following torque. ........................... 2.6 to 4.6 N·m (23.0119 to 40.7134 lb in) No load conditions at 25 °C (77 °F) Speed .................................. 3000 rpm minimum Current draw ......................... 200 amp maximum Voltage .. . . ........... .. .. ......... ..... ......... ..... ... .... . .. 11 V When the electric starting motor is viewed from the drive end, the motor rotates in the following direction .................................................... Clockwise

24 Specifications Section

SENR9833-02

i01899831

Glow Plugs

Current (30 second rating) .................... 5.5 amperes

Naturally Aspirated Engines

Illustration 53

900988137

{1) Tighten the glow plugs in the cylinder head to the following torque. ...... 15 to 20 N¡m (11 to 15 lb ft) Type ............................................................... 12 Volt Current (30 second rating) .................... 9.7 amperes

Turbocharged Engines

Illustration 54

g00988138

(1) Tighten the glow plugs in the cylinder head to the following torque ...... 20 to 30 N¡m (15 to 22 lb ft) Type .............................................................. 12 Volt

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SENR9833-02

25 Index Section

Index A

L

Alternator and Regulator ....................................... 23

Lifter Group............................................................

B

M

Belt Tens ion Chart ................................................. 22

Main Bearing Journal............................................. 17

C

p

Camshaft...............................................................

Connecting Rod.....................................................

ConnectingRod Bearing Journal...........................

Crankshaft ............................................................

Crankshaft Pulley ..................................................

Crankshaft Seals ...................................................

Cylinder Block........................................................

Cylinder Head........................................................

Cylinder Head Valves ............................................

9 17 17 16 21 17 14 9 8

23 4 12 13 12 11 11 9

R Roc ker Shaft.......................................................... 7

s

T Table of Contents................................................... 3 Turbocharger........................................................27

V Valve Mechanism Cover........................................ 7

w

F Flywheel ................................................................

Front Housing and Covers.....................................

Fuel Injection Lines................................................

Fuel Injec tion Pump...............................................

Fuel Injectors.........................................................

Naturally As pirated Engines...............................

Turbocharged Engines.......................................

Fuel Trans fer Pump...............................................

Piston and Rings ................................................... 18

Specifications Sec tion........................................... 4

E Electric Starting Motor ...........................................

Engine Des ign.......................................................

Engine Oil Bypas s Valve .......................................

Engine Oil Pan.......................................................

Engine Oil Pres s ure...............................................

Engine Oil Pump....................................................

Engine Oil Relief Valve..........................................

Exhaus t Manifold...................................................

6

21 20 4 4 5 5 6 6

G Gear Group (Front) ................................................

Engines that have a Balancer............................

Glow Plugs ............................................................

Naturally As pirated Engines...............................

Turbocharged Engines .......................................

20 21 24 24 24

Important Safety Information.................................

2

Water Temperature Regulator ............................... 14

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TURBOCHARGER MANUAL for use with Terex PT80 Build 804C-33T

Turbocharger Rebuild Kit Reference # 49189-Z3821

INTRODUCTION

This Service Manual is written to familiarize you with the construction and maintenance of Turbochargers.

Long life and efficient performance are the essential qualities required of the turbochargers if they are to fulfil their function of turbocharging the engines. These qualities depend to a great extent on the care exercised in maintenance of the turbochargers.

We hope you read this manual carefully, preferably referring to the separate parts catalogue, to get to know your new turbochargers and learn how to service them before starting disassembly, inspection,- cleaning, repair and reassembly.

The description, illustrations and specifications contained in this manual were of the turbochargers manufactured at the time this manual was approved for printing.

Mitsubishi reserves the right to change specifications or design without notice and without incurring obligation.

HOW TO USE THIS MANUAL

1. The parts read in the texts or shown in the illustrations are numbered in the disassembling sequence prescribed for each system or assembly.

2. The items to be inspected during disassembly are indicated in disassembled view.

D

in the

3. The . maintenance standards to be referred to for inspection and reassembly are indicated in easy-to-refer passages of the texts and also in MAINTENANCE STANDARDS in a tabulated form.

4. The sequence in which the parts are to be reassembled are shown in the form of, for example, @-Ž-Š-@--(!), below the assembled view.

5. The following marks are used in this manual:

NOTES, CAUTIONS and WARNINGS NOTES, CAUTIONS and WARNINGS are used in this manual to emphasize important and critical instructions.

They are used for the following conditions: [NOTE]

. .&[ CAUTION l

.....

An operating procedure, condition, etc., which is essential to highlight .

Operating procedures, practices, etc., which if not strictly observed, will result in damage to or destruction of turbocharger.

Op�rating procedures, �WhW!Uil ···- etc., which if not

practices, correctly followed, will result in personal injury or loss of life.

DEFINITION OF TERMS In this manual, the following terms are used in the dimensional and other specifications: NOMINAL VALUE ..

Indicates the standard dimension of a part.

ASS EM BLY STANDARD

Indicates the dimension of a part, the dimension to be attained at the time of reassembly or the standard performance. Its value is rounded to the nearest whole number needed for inspection and is different from the design value.

STANDARD CLEARANCE ..... Indicates the clearance to be obtained between mating parts at the time of reassembly.

REPAIR LIMIT . . . . . . . . . . . . . . A part which has reached this limit must be repaired.

SER VICE LIMIT . . . . . . . .. .. . . A part which has reached this limit must be replaced.

DESCRIPTION

DESCRIPTION Thrust bearing

Turbine wheel

Air inlet Exhaust â&#x20AC;˘ gas outlet

Compressor cover Bearings

The turbocharger consists of a mixed-flow turbine, driven by the exhaust gases coming from the engine, a centrifugal air compressor for pumping air toward the inlet manifold of the engine, and a shaft common to the turbine and compressor.

The turbocharger supplies a larger amount of inlet air to the engine than the amount it can draw in naturally aspirated condition.

For those diesel engine applications needing not so high "boost" (manifold) pressures, the larger amount of inlet air that turbocharging makes available eliminates sooty exhaust smoke, reduces the chances of engine overheating (by keeping down the cylinder temperature), improves fuel economy and does away with the need of engine derating at higher altitudes.

There are applications requmng more power from a given size of engine. For

Exhaust gas inlet

Turbine housing 401700

such applications, turbocharging meets the requirement by enabling the engine to convert more fuel into a large power output.

The high turbocharger technology of Mitsubishi is reflected in these turbochargers in terms of performance, reliability and durability. In comparison with other turbochargers, these five models feature separated-type bearings for supporting close to the ends of the shaft on which a greater part of rotary mass is concentrated during operation.

Other features are a shaft made slenderer to reduce the loss due to high-speed rotary friction and a separated-type turbine back plate designed to block more effectively the flow of heat from turbine side to bearing housing.

DISASSEMBLY

DISASSEMBLY

Vane distortion, damage,

signs of rubbing contact on back face and gas

erosion

Thrust face wear

© Signs of rubbing contact with turbine wheel and distortion

,-----------,

:a�· i I

7

:

,

�®

:

:

I

I I

'----

TD025 I --- _____

Damage and gas erosion of bearing hole and distortion of turbine-side flange

)

401701

CD ® @ © @ ® (J)

Hose Actuator Coupling assembly Turbine housing Snap ring Compressor cover O-ring (shim for TD025) ® Lock nut

® @) @ @ @ ® @) @

Compressor wheel @ Oil deflector Shaft & turbine wheel @ Thrust sleeve @ O-ring Piston ring Turbine back plate ® Thrust bearing @ Thrust ring Bearing @ Bearing Snap ring @ Snap ring Insert ® Snap ring Piston ring ® Bearing housing

,-------&[CAUTION) ---The vanes of compressor wheel and turbine wheel are not quite strong and can easily be distorted.

When handling these wheels, be careful not to drop or shock them.

2

DISASSEMBLY

1. Removal of actuator Disconnect hose (1) from actuator, and remove actuator (2).

-------[NOTE]---------,

To disconnect the rod of actuator (2) from turbine housing (4), pull off snap pin at the lever joint.

401702

2. Removal o_f turbine housing Loosen coupling assembly (3), as shown, and separate turbine housing (4) from bearing housing (25).

® ®

-------�------�

©

Before separating the three enclosure parts, namely, compressor cover (6), bearing housing (25) and turbine housing (4), be sure to give match marks across each joint. A punch or quick-drying ink pen may be used.

401703

3. Removal of compressor cover (1) Lay compressor cover (6) flat on the table, as shown. Using the snap ring pliers (A) (49160-90100), take off snap ring (5).

-----.&f141;1t@@----� Hold down the snap ring by hand while pinching the ring ends with the snap ring pliers, so that the ring will not fly off just in case the ring ends slip off the pliers.

401704

3

DISASSEMBLY

(2)

Using a plastic hammer, lightly tap around on compressor cover (6) to remove the cover.

Remove the O-ring or shim (TD025) (7) from the bearing housing.

..----- .&J

CAUTION]---�

Be careful not to bump the compressor wheel against the cover.

® 401705

4. Removal of compressor wheel (1)

Hold turbine housing (4) in a vise, as shown. Fit the removed bearing housing (25) to the housing, and secure it temporarily with coupling.

Shaft & turbine wheel (10) is now back in the turbine housing and compressor· wheel (9) is on top.

While holding the boss part of turbine wheel as shown, loosen off lock nut (8) from the shaft.

(2)

401706

Put your hand to the turbine wheel and, while holding this wheel, turn compressor wheel (9) back and forth with the other hand to lift it off the shaft.

401707

5. Removal of snap ring Using the snap ring pliers (A) (491 60-90100), remove snap ring (14).

�----&tM1Mi@ri----Hold down the snap ring by hand while pinching the ring ends with the snap ring pliers, so that the ring will not fly off just in case the ring ends slip off the pliers.

4

401708

DISASSEMBLY

6. Removal of insert, oil deflector and others Using two screwdrivers, gently lift insert (15) • off bearing housing (25).

Remove the following parts: @ @ @ @ ® ®

Piston ring Oil deflector Thrust sleeve 0-ring .

Thrust bearing Thrust ring

401709

�------�------------, In reassembling, position snap ring (14) with its flat side facing insert (15).

7. Removal of shaft &. turbine wheel and bearing (1)

(2)

Lift bearing housing (25) complete with shaft &. turbine wheel (10) off turbine housing (4) held in the vise, with one hand holding the shaft and with the other hand holding the bearing housing (25). Be careful not to damage the vanes as the shaft &. turbine wheel clears turbine housing (4).

401710

Turn bearing housing (25) upside down (with the turbine wheel up), and lay it on compress or cover. Under this condition, remove the following parts: (To remove shaft &. turbine wheel (10), lightly tap on its end with a hammer handle.) @) (jJ) @ @)

Shaft &. turbine wheel Piston ring Turbine back plate Bearing (turbine side)

5

DISASSEMBLY

8. Removal of snap rings and bearing Lay bearing housing (25) on the bench with the co mpressor side up, and remove the following parts: ® Bearin� } (co mpressor side) @ Snap rmg ® Snap ring (turbine side) �----[NOTE]----� 401712

a) Use the snap ring pliers (49160-90200) to remove the snap rings. b) When removing the snap ring, be careful not to da mage the inside surface of bearing housing and sealing face (turbine side) of piston ring.

6

CLEANING AND INSPECTION

CLEANING AND INSPECTION 1. Cleaning Blasting· equipment is used in the factory to clean turbochargers. At the dealer level, the following cleaning method, based on the use of a non­ inflammable solvent (for which Die Cleaner T-30 of Daido Chemical make is recommendable), may be applied: --- --[NOTE]----�

Non-sudsing household detergent may be used instead of the solvent. In such a case, be sure to select one that is chemically neutral and does not attack metals.

(1)

Visually inspect the parts to detect signs of burning and other mal­ conditions in order to obtain as much possible before information as washing them.

(2) Immerse the parts in the washing pan filled with the solvent, and wash each clean, making it completely free of oily matter.

(3) Take out the washed parts and dry them by directing compressed air: blow off the solvent from every nook and corner of each part.

(4) Scale-like deposits, if any, must be removed by using a plastic scraper or bristle brush. After removing the deposits off, wash the part and dry it again as before.

400364

¢ 400660

�---&[CAUTION]---�

When washing and drying the parts, handle them cautiously and avoid denting or nicking them.

(5) Protect the sliding surfaces of the cleaned parts against rusting by applying clean engine oil to them.

400661

7

CLEANING AND INSPECTION

2. Inspection (1)

Bearing housing Measure the inside diameter of bearing bores in the housing. If it exceeds the Service ¡limit, replace the housing.

Unit: mm (in.)

Service limit

Item

13.006 (0.51205)

Inside diameter of bearing bores in housing

(2) (a)

Bearing Measure the the bearing. the Service bearing.

outside diameter of If it is less than limit, replace the Unit: mm (in.)

Service limit

Item Outside diameter of bearing

(b)

400367

I

12.924 (0.50882)

I

400368

Measure the inside diameter of the bearing. If it exceeds the Service limit, replace the bearing.

Unit: mm (in.)

Item

Inside diameter of bearing

I I

u

Service limit 7.529 (0.29642)

I

â&#x2013;Ą 400369

(c)

Measure the length of the bearing. If it is less than the Service limit, replace the bearing.

Unit: mm (in.)

Item

Length of bearing

Service limit

I

7.94 (0.3126)

I 400370

8

CLE-ANING AND INSPECTION

(3) Shaft & turbine wheel (a)

Measure the diameter of the shaft journals. If it is less than the Service limit, replace the shaft & turbine wheel and piston ring.

Unit: mm (in.)

Item

Diameter of shaft journals

I

Service limit

I 7.496

I

(0.29512)

(b)

400371

Using a dial indicator and V-block, measure the runout of the shaft. If it exceeds th§l Service limit, replace the shaft & t\Jrbine wheel.

Unit: mm (in.)

Item

Runout of shaft & turbine wheel

Service limit

J

0.0 I 5 (0.00059)

.-------[NOTE]----ďż˝

400372

Do not attempt to straighten a distorted shaft. Be sure to replace the shaft & turbine wheel with a new one when the shaft is distorted. (c)

(4)

Check the surfaces of shaft journals for condition. If they are roughened, hold the shaft on a lathe by tightening it in the chucks at its center, and turn it at 300 to 600 rpm to lightly polish the journals with #400 sandpaper and engine oil.

Insert Place a new piston ring in the groove in the insert, and measure the end gap of the ring. If the gap exceeds the Standard clearance, replace the insert.

Insert Piston ring

Unit: mm (in.)

Item End gap of piston ring

Standard clearance

0.05 - 0.15 (0.0020 - 0.0059)

400665

9

REASSEMBLY

REASSEMBLY

2

9

401713

I

Reassembling sequence

I

.--------- [NOTE]-------.

,------&_[CAUTION] ----,

a) Replace the following parts when reassembling the turbocharger:

Replace the compressor wheel or shaft & turbine wheel if its vanes are badly distorted or cracked.

A single blade having minor distortion or scratching is not the cause for replacement; in such a case, never attempt to re-shape the distorted vane.

@ Piston ring @ Piston ring

@ 0-ring (J) 0-ring

b) After installing an overhauled turbocharger on the engine, crank the engine with the starter to permit the engine oil to flow to the turbocharger.

10

REASSEMBLY

1. Installation of shaft &: turbine wheel and bearings (1)

Reassemble the following parts: @ � @ @ @ @)

Bearing housing Snap ring Snap ring Bearing Piston ring Shaft &:. turbine wheel

�---- &[CAUT ION]---� a)

Use the snap ring pliers (49160-90200) to install the snap rings. After installing the snap ring, make sure that it can be finger rotated freely.

b) Apply engine oil to the inside and outside surfaces of bearing when installing the bearing to the shaft. c) When installing the piston ring to the shaft &: turbine wheel, be careful not to expand the ring more than is necessary for installation nor to twist it. d) After installing the piston ring in its groove, apply Molykote to it.

Lay bearing housing (25) on compressor cover (6) and install turbine back plate (12).

(2)

Wherr installing shaft & turbine wheel complete with piston ring to the bearing housing, position the piston ring as shown, and insert the shaft &: turbine wheel into the housing while rotating it back and forth.

: : st

End gap

,------&[CAUTION]---� Never force the shaft & turbine wheel unless it is in line with the turbine back plate and bearing housing.

401715

11

REASSEMBLY

(3) After installing shaft & turbine wheel (10), hold the end of shaft by hand, and turn it upside down so that its compressor side is up. Then, install compressor-side bearing (22).

Temporarily install bearing housing (25) to turbine housing (4), and install coupling assembly (3) by tightening its nut temporarily. �---·.&_[CAUTION]----

r----© 401716

Hold the shaft by hand to prevent it from sliding out of position during installation.

2. Installation of thrust bearing Apply engine oil to the inside and outside surfaces of thrust ring (21) and thrust bearing (20), and install the ring and bearing in place.

401717

3. Installation of 0-ring Apply engine oil to 0-ring (19), and install it in place.

401718

12

REASSEMBLY

4. Reassembly of insert subassembly Reassemble the insert parts in the following sequence:

(1)

@ @ ÂŽ @

Oil deflector Thrust sleeve Piston ring Insert

ďż˝---_&.[CAUTION]------,

@

l 401719

a) When installing the piston ring to the thrust sleeve, be careful neither to expand the ring more than is necessary for installation nor to twist its end gap. b) Apply fitted install taking ring.

Molykote to the piston ring to the thrust sleeve, and the sleeve to the insert, care not to damage the

(2) Install the insert subassembly bearing housing (25).

to

5. Installation of snap ring

ring pliers snap install snap ring (14) to bearing housing (25 ), with its tapered side facing upward.

Using

the

(49160-90100),

401720

----.&.[CAUTION]------, a) Be sure to position the snap ring as specified above when installing it. b) Give light hammer blows to the ends of snap ring through a screwdriver to fit the ring in the groove in the bearing housing. c) When giving hammer blows to the snap ring, be careful not to damage the bearing housing.

13

REASSEMBLY

6.

Measurement of clearance between turbine wheel and turbine housing Set up a dial indicator on shaft & turbine wheel (10} as shown. Move the shaft in the· axial direction to measure the clearance. If the clearance is out of the Standard clearance, disassemble the parts, and investigate for the cause.

.

Item

Clearance between shaft & turbine wheel and turbine housing

Unit: mm (in.)

Standard clearance

@

401722

0.280.97 (0.0110 0.0382)

7. Installation of compressor wheel Install compressor wheel (9), apply Molykote to the lock nut and tighten it to the specified torque.

Item

Compressor wheel lock nut

Unit: kgf-m Obf•ft) [N•mJ

Tightening torque 0.400.50

Sho r�; 1? .

Compressor wheel side

401723

8. Measurement of axial play of shaft & turbine wheel Set up a dial indicator on shaft & turbine wheel (10) as shown. Move compressor wheel (9) in the axial direction to measure the play. If the play is out of the Standard clearance, disassemble the parts, and investigate for the cause.

Item

Axial play of shaft & turbine wheel

14

Unit: mm (in.)

Standard clearance I

0.057 - 0.103 (0.00224 -0.00406)

401724

REASSEMBLY

9. Measurement of clearance between turbine back plate and turbine wheel Remove the turbine housing from and install bearing housing (25), compressor cover (6).

Using filler gauges, measure the clearance between turbine back plate (12) and turbine wheel. If the clearance is out of the Standard clearance, disassemble the parts, and investigate for the cause.

401725

..--------ďż˝------ďż˝ Measure the clearance at the tips of vanes with two feeler gauges.

Item Clearance between turbine back plate and turbine wheel

Unit: mm (in.)

Standard clearance

0.39 0.83 (0.0154 0.0327)

10. Installation of compressor cover Install compressor cover (6), making sure that it is correctly positioned with respect to the turbine housing.

Apply grease to 0-ring (7) when installing it.

11. Installation of snap ring

401726

Using the snap ring pliers (49160-90100), install snap ring (5) to compressor cover (6), with its tapered side facing upward. ..--------[NOTE],------ďż˝ a) Be sure to position the snap ring as specified above when installing it. b) Give light hammer blows to the ends of snap ring to fit the ring in the groove in the bearing housing.

401727

15

REASSEMBLY

12. Installation of turbine housing Install turbine housing (4) to bearing housing (25), making sure that it is correctly positioned with respect to the housing.

401728

13. Installation of coupling assembly Apply Molykote to the threads of nut of coupling assembly (3), and tighten the nut to the specified torque.

Unit: kgf·m (!bf-ft) [N-m] Item Coupling assembly nut

Tightening torque TD03/TD04 0.400.50 (2.9 - 3.6)

®

401729

14. Installation of actuator Install actuator (2) in place, connect hose to actuator.

and

�------[NOTE]--------,

After installing actuator body (2) to compressor cover (6), connect its rod to the lever of turbine housing (4) with snap pin.

16

401702

TROUBLESHOOTING

Symptom Rough running (abnormal running noise or vibra­ tion)

. Possible causes and remedy (1) Bearing could be in faulty condition or rotating

parts, particularly wheels, could be rubbing surrounding parts. This type of trouble is often caused by keeping a deteriorated lubricating oil in service, by inadequate oil supply due to a clogged oil pipe or broken or clogged oil filter, or by habitual quick cold starting or abrupt shutting down of a hot engine.

(2) Evfdence of rubbing contact on rotating parts indicates loss of balance in rotating mass or a distorted shaft, caused by a worn-down bearing or by an airborne or gasborne object impinging upon the compressor or turbine wheel to disturb its mass distribution.

In either case, turbocharger must be taken down and inspected. Usually repair service is required.

Turbocharger appears to be in sound condi­ tion but engine lacks power.

(1) Exhaust gases could be leaking. Check exhaust

gas line from engine manifold to turbocharger gas inlet.

(2) Abnormally high back pressure to turbocharger's exhaust gas outlet could be the cause. Check muffler for clogging with carbon.

(3) Boost air could be leaking or air cleaner could be in clogged condition. If clogged, clean or replace element.

(4) Compressor interior could be dirty with excessive dust accumulation. If this happens to be the case, remove compressor cover and clean.

(5) After shutting down engine, try to spin rotor by hand. If rotor will not spin, disassemble turbocharger and clean.

17

Symptom

Possible causes and remedy

Oil leaks from exhaust gas -outlet pipe or from inlet airâ&#x20AC;˘ pipe.

(1) A clogged air cleaner is liable to create a negative-pressul'e condition on suction side to draw in lubricating oil. Clean or replace element.

Exhaust smoke tends to pick whitish color.

(2) Inspe_c t lubricating .oil return pipe for damage.

A dented or distorted pipe must. be repaired or replaced.

(3) See if piston ring is worn down or, because of its groove being worn down, loose in groove: if so, replace worn parts.

(4) Keeping turbocharger in service with its bearing in faulty condition will damage piston ring in time, resulting in leakage of oil into both ends, that is, gas outlet pipe and inlet air pipe.

18

MAINTENANCE STANDARDS

MAINTENANCE STANDARDS

1. Maintenance standards Unit: mm (in.)

Part or item Inside diameter of bearing bores in bearing housing

Nominal value

AssemblY. standard [Standard clearance)

Remarks

12.924 (0.50882)

diameter

Inside diameter

Service limit [Clearance) 13.006 (0.51205)

13.0 (0.512)

Outside

Bearing

Repair limit [Clearance)

7.529 (0.29642)

TD03/TD04

7.94 (0.3126)

Length

Diameter Shaft & of shaft turbine journals wheel

7.496 (0.29512)

7.5 (0.295)

0.015 (0.00059)

Runout of shaft End gap of piston ring Clearance between shaft & turbine wheel and turbine housing Axial play of shaft & turbine wheel

o.o5 - 0.15 [co.0020 - 0.0059)l

l

With ring fitted in insert

[ 0.28 - o.97 l (0.0110 - 0.0382)

l

0.57 - 0.103 0.00224 - 0.00406

19

MAINTENANCE STANDARDS

Unit: mm (in.)

Part or item

Nominal value

Assembly standard [Standard clearance]

Repair limit [Clearance]

Service limit [Clearance]

Remarks

o.39-o.83 l [(0.0154 -0.0327)

Clearance between turbine back plate and turbine wheel

l

2. Tightening torques Thread Diam. - pitch

Width across flats

Compressor wheel Jock nut

5 -0.8 (0.20-0.03)

8(0.31) 0.40-0.50

2.9-3.6 3.9-4.9

Apply Molykote to threads

Coupling assembly nut

6-1.0 (0.24-0.04)

JO (0.39) 0.40-0.50

2.9-3.6 3.9-4.9

Apply Molykote to threads

Secured part or component

Tightening torque kgf-m

!bf-ft

N-m

Perkins 804C-33T Turbocharger Rebuild Kit Reference: 49189-Z3821

20

Remarks