帕金斯發動機渦輪增壓器的維修保養技術參數資料3012

To remove

1  Remove the air ducts between the air cleaner, the

turbocharger and the radiator.

2  Disconnect the pipe that supplies oil to the

turbocharger.  Disconnect also the drain pipes.

3  Disconnect and remove the exhaust pipe from the

elbow and remove the elbow, and the exhaust

bellows if relevant.

4 If relevant for early engines, bend back the tabs of

the lock washers on the bolts that retain the

turbocharger.  Remove the bolts and lift away the

turbocharger from the engine.  For new engines,

release the four nuts which hold the turbocharger to

the exhaust manifold; remove the plain washers and

lift away the turbocharger.

1 Ensure that there is no internal contamination of the

castings of the induction manifold and the exhaust

manifold.  Check that they are not damaged and that

there is no erosion on the joint faces.  Check that the

pipes for the supply of lubricating oil and the drain

pipes are clean, and that they are not damaged.

2 Ensure that the joint faces of the turbocharger and

the exhaust manifold are absolutely clean. Ensure

that the stainles s steel studs in the joint face of the

exhaust manifold are not damaged and apply

’Copaslip’ anti-seize compound to the threads.  Put

the turbocharger on the joint face of its exhaust

1

for the oil. Put 0,2 litre ( / pint) of clean engine

manifold and retain with the four stainless steel nuts

and the plain washers.  Tighten securely the nuts.

3 Refit the exhaust bellows if relevant, the elbow and

the exhaust system.

4  Use new hoses to fit the air ducts between the

turbocharger, the radiator and the air filters.

5  Before the engine is started, the bearings of the

turbocharger must be flushed with lubricating oil.

Clean around the blanking plug (A1) on the bearing

housing and remove the blanking plug from the inlet

lubricating oil into the bearing housing through the

inlet.  Fit and tighten the blanking plug.

Caution: After a complete engine overhaul, a s pecial

temporary filter for the engine lubricating oil must be

fitted to the oil inlet of each turbocharger. The special

filters are not usable again, and must be removed and

discarded after the first period of running-in of the

engine.

o dismantle and to assemble

To dismantle

5 Hold upright the bearing housing and use a socket

or spanner with a tee handle to remove the nut (A14)

which retains the impeller of the compressor.

Caution: To prevent distortion, ensure that a

The relevant kit of service parts must be used when a

turbocharger is dismantled and assembled.

1  Clean the outside of the unit and use a scriber to

mark the relationships of the housings for the

bearings (A10), the compressor (A1) and the turbine

(A16).

2  Remov e the bolts (A3) and the clamps (A2) which

hold the housing of the compressor.  Use a soft faced

hammer to remove the housing.  Ensure that the

impeller of the compressor (A4) is not damaged

during the operation. Remove and discard the ’O’ ring

(A5).

3  Loosen the stiffnut (A17) of the ’V’ band clamp

(A18) and disengage the clamp from the flanges of

the turbine housing and the central bearing housing.

Do not press on the rotating assembly.

4  Select a socket, or a suitable spanner, of the

correct size to fit the hexagon extension on the hub of

the turbine rotor (A7) and securely fasten it in a vice.

Fit the hexagon extension in the socket or spanner.

bending moment is not applied to the shaft.

6  Use a suitable support to hold upright the bearing

housing, with the impeller of the compressor at the

top. Press the shaft of the turbine out of the housing.

The shroud (A9) of the turbine is also removed with

the shaft.

7  Remove and disc ard the piston ring ty pe seal (A8)

at the turbine rotor end of the shaft.

8 Release the bolts (A13) which retain the assembly

of the backplate (A6) and remove the assembly of the

backplate and the sealing ring (A23).  Discard the

sealing ring.

9 Remove the spacer (A21) from the assembly of the

backplate.  Remove and discard the two piston type

rings (A22) from the spacer.

 

10 Remove three sc rews (A15) that fasten the thrust

plate (A12) to the bearing housing.  Remove the

thrust plate and the collar (A20).

11 Remove the circ lips  (A11) and the bearings (A19)

from the bearing housing and discard the bearings.

To assemble

Caution: Before the turbocharger is assembled,

lubricate lightly all bearing surfaces with clean engine

lubricating oil.  The circlips which retain the bearings

have round shoulders on one side.  When they are

assembled, ens ure that the sides with the round

shoulders are toward the bearings.

1 Fit the inner c irclips of both bearings in the bore of

the bearing housing. Ensure that the round shoulders

are on the outer faces of the circlips.

2 Fit a new bearing in the bore of the bearing housing,

at the end for the turbine housing.  Retain it by

another circlip, fitted with the round shoulder on the

inner face.

3 Fit a new bearing in the bore of the bearing housing,

at the end for the compressor.  Assemble the collar

and thrust plate, and install the assembly in the

bearing housing.

Caution: All the threaded holes in the turbocharger

are metric.

4 Retain the collar and the thrust plate in the bearing

housing with three screws and tighten them to 2,5 Nm

(22 lbf in).

5  Fit a new seal and assemble the backplate to the

bearing housing.  Retain with four bolts and tighten

them to 9,0 Nm (80 lbf in).

6  Fit a new piston ring type seal to the shaft of the

turbine rotor.

7  Assemble the shroud of the turbine rotor over the

shaft and insert carefully the shaft through the

bearings.  Turn and move carefully the shaft in

various directions to allow the piston ring type seal to

enter its seat in the bore.  Do not apply force because

the piston ring type seal can be broken easily.

8  Assemble the new piston ring type seals on to the

spacer.  Fit the spac er over the shaft and carefully

compress the seals to insert it into the assembly of the

backplate.

9  Put the assembly of the bearing housing in a

suitable support to hold it upright and fit the impeller

of the compressor on to the shaft.

10  Lubricate lightly the threads of the shaft and the

contact face of the nut which retains the impeller. Fit

the nut and use a socket or a spanner with a tee

handle to tighten the nut to a torque of 3,6 to 4,7 Nm

(32 to 42 lbf in).

Caution: To prevent distortion, ensure that a

bending moment is not applied to the shaft.

11  Ensure that the faces of the impeller and the

spacer are in contact and tighten the nut another 120°

to extend the shaft 0,20 to 0,23 mm (0.008 to 0.009

in).

12  Put loosely the 'V' band clamp on the bearing

housing and apply some 'Copaslip' anti-seize

compound to the threads of the 'T' bolt.  Hold the

turbine housing in the correct position and fit the 'V'

band c lamp.  Tighten the stiffnut to approximately

18,1 Nm (160 lbf in), loosen to approximately 5,6 Nm

(50 lbf in) and tighten again to approximately 17,0 to

19,2 Nm (150 to 170 lbf in).

13  Fit a new 'O' ring on the outer lip of the backplate

assembly. Hold the housing of the compressor in the

correct position and fit the clamps and the bolts.

Tighten the bolts to a torque of 9,0 to 11,3 Nm (80 to

100 lbf in).

14  Check the rotating assembly for interference.  If

interference occurs, find the fault and ensure that it is

corrected.

15  Check the end float and the radial movement of

the rotating assembly.

16 Set the tip of a dial test indicator in contact with the

end of the turbine rotor (A). Move manually in an axial

direction the shaft of the turbine rotor.  Do not allow

the shaft to move radially. The total end-float must be

between 0,05 mm and 0,08 mm (0.002 and 0.0032

in).

17  A dial test indicator with an extended plunger is

required to measure the radial movement of the shaft.

Insert the plunger through the oil supply hole of the

bearing housing so that the end of the plunger is in

contact with the side of the shaft.  The turbocharger

assembly and the dial test indicator must be

supported firmly.  Hold the turbine shaft at both ends

and move it carefully towards and away from the

plunger to the limits  of its movement. Ensure that an

equal amount of movement is applied to both ends of

the turbine shaft and check the reading on the dial test

indicator.  The radial movement must be between

0,12 and 0,17 mm (0.0048 and 0.0065 in).

18  If the unit is to be held in storage, lubricate the

inner components and seal all openings.

帕金斯發動機渦輪增壓器的清潔和檢查

1  Before all the components are cleaned, inspect

them for burning, for rubbing and for other damage

that may not be seen easily after they  are cleaned.

2 Soak all the components in a non-caustic cleaning

fluid and use a brush, or a scraper that is made of

plastic, to remove all the loosened depos its.  Ensure

that all surfaces are clean, especially the bearing

surfaces and the bores of the bearing housing;

remove loose particles with dry compressed air.  Do

not remove the s urface finish. Check especially inside

the bearing housing and ensure that it is absolutely

clean.

3  Check all the permissible worn dimensions which

are giv en in at the end of this section.

4  Renew the bearing housing if the bores for the

bearings or the piston type seals have deep

sc ratches, or are worn.  Very small scratches are

acceptable.

5 Inspect the journals of the shaft for wear, scratches

or other marks. A fine abrasive can be used carefully

to remove very small s cratches.  The component  is

unserv iceable if there are deeper scratches and other

indications of wear.

6  Inspect the groove for the piston ring type seal for

wear and scratches.  Small scratches are acceptable.

7  Inspect the turbine rotor for distortion, for erosion,

for cracks, for signs of friction and for damage caused

by impact. A small amount of erosion is acceptable if

the thickness at the tip of the blade is not less than 0,6

mm (0.025 in), and no other damage is existent.  Do

NOT try to correct a bent blade.

8  Ensure that the bore of the backplate is  not worn

within the area of the piston type seal. Check that the

thrust face is clean and smooth.

9 If necessary, a fine abrasive can be used carefully

to obtain smooth faces.

10 Remove the two piston ring type seals and inspect

the grooves in the spacer for wear and scratches.

Step type wear is not permissible.

11  Discard and renew the thrust plate and also the

bearings for the journals.

12 Renew the impeller of the compressor if there are

signs of friction, of erosion or of other damage.

13  Renew the shroud if it is distorted or eroded, or if

it has marks which are caused by friction.

帕金斯發動機渦輪增壓器允許磨損尺寸

Fits and clearances

Turbocharger permissible worn dimensions

Bearing housing

 

Bore of bearing (maximum diameter)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20,188 mm (0.7948 in)

Bore of seal (maximum diameter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20,930 mm (0.8240 in)

Shaft of turbine rotor

Journal of bearing (minimum diameter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  12,992 mm (0.5115 in)

Groove for piston ring type seal (minimum diameter) . . . . . . . . . . . . . . . . . . . . . . . . . .  17,475 mm (0.6880 in)

Groove for piston ring type seal (minimum width) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1,740 mm (0.0685 in)

Hub (minimum diameter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  19,960 mm (0.7860 in)

Turbine rotor

Blade tips (minimum thick ness). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  0,64 mm (0.025 in)

Backplate

Bore of seal (maximum diameter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  17,500 mm (0.6890 in)

Collar

Groove in collar (maximum width) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4,440 mm (0.1748 in)

Bore of collar (maximum diameter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7,945 mm (0.3128 in)

Spacer

Outside of spacer (minimum diameter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  17,056 mm (0.6715 in)

Bore of spacer (max imum diameter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7,945 mm (0.3128 in)

Groove for piston ring type seal (maximum width)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1,765 mm (0.0695 in)

Thrust plate

Pads (minimum thicknes s)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4,359 mm (0.1716 in)

Bearing

Outs ide of bearing (minimum diameter)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20,068 mm (0.7901 in)

Bore of bearing (maximum diameter)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  13,038 mm (0.5133 in)

Impeller of compressor

Bore of impeller (maximum diameter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7,935 mm (0.3124 in)

Shroud of turbine rotor

Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  Renew if damaged

Turbine housing

Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  Renew if there is distortion or other damage

Housing of compressor

Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  Renew if there is distortion or other damage