05-air in - exh - turbo (R1.4jb)

Air IntakeandExhaust : 

Air IntakeandExhaust

Slide 2: 

Air Cleaner System Filter Media Dust Cup Screen

Slide 5: 

Air Cleaner Fiber New fiber Dust particle, being denser than air, has too much velocity to go around fiber, so particle hits and imbeds on fiber Used fiber

Slide 6: 

Centrifugal Type Air Cleaner

Air Cleaner System : 

Air Cleaner System Centrifugal types Baffle plate Dust evacuator What makes it discharge particles?

Air Intake Systems : 

Air Intake Systems Air Cleaner Styles (Kubota / After-market) Plastic / Steel / Pre-cleaners Single / Dual Element / Minders Safety element

Slide 9: 

Air Cleaner System Radial Seal type Air filter element seats on tapered “cone” in end of canister.

Slide 10: 

Air Cleaner System Check for good seating of sealing washer Check for good seating of air cleaner element against base of air cleaner housing. Conventional type

Slide 11: 

Air Cleaner System Lip type seal, as air intake restriction increases, lip seal tightens NOT ALL SEALS ARE GOOD! This type of seal cost big $$$$$ Square type seal

Slide 12: 

Air Cleaner System Inspection of element Any problems?

Slide 13: 

Air Cleaner System Poor air inlet system security, abrasive dust can enter inlet and engine failure results.

Air Intake Systems : 

Air Intake Systems Air Cleaner Location / Mounting Intake Air Temperature

Slide 15: 

Output De-rate (altitude and inlet temp.)

Air Intake Restriction : 

Air Intake Restriction Naturally aspirated: High Idle engine speed during test: Turbocharged: Full load, max rpm Measuring inlet restriction

10. Exhaust back Pressure : 

10. Exhaust back Pressure Check exhaust system has no excessive back pressure? Performance with muffler removed? 1mmHg = 0.535inAq Manometer Location

Exhaust Systems : 

Exhaust Systems Calculations / Measurements Calculating Back Pressure Vibration

Turbochargers : 

Turbochargers

What is a Turbocharger? : 

What is a Turbocharger? Superchargers and turbochargers are devices which increase the density of air going into an engine A supercharger is a constant volume blower that is belt driven by the crankshaft A turbocharger is a centrifugal compressor that is driven by an exhaust gas turbine

Turbocharger vs. Supercharger : 

Turbocharger vs. Supercharger Both are driven by the crankshaft, a Supercharger by belt, a turbocharger by the exhaust stroke pushing gas through the turbine

Efficiency : 

Efficiency Turbine is more efficient that belt drive Turbocharger can take advantage of exhaust gas energy (heat and pulse) that is wasted with a supercharger Residual/parasitic losses are lower with a turbocharger

Why a Turbocharger? : 

Why a Turbocharger? Power Density: Increased air density (pressure) means you can inject more fuel and get more power per displacement Air Control: Increased air supply reduces particulates and emissions Altitude Correction: Derate for altitude is much less because turbocharger moves mass not volume

TurbochargerAltitude De-rate : 

TurbochargerAltitude De-rate Engines move air volume, so they move less air at altitude where air is less dense. When air temperature increases, density also reduces Turbochargers use centrifugal force to move mass, so de-rate is much lower.

Turbocharger Air Flow : 

Turbocharger Air Flow

Turbocharger Oil Flow : 

Turbocharger Oil Flow

Turbocharger Bearings & Seals : 

Turbocharger Bearings & Seals

Turbocharger Waste-gate : 

Turbocharger Waste-gate Limits boost by letting exhaust gas bypass the turbine wheel Boost pressure pushes on diaphragm and spring and pushes open gate valve when boost setting is reached

Why Waste-gate : 

Why Waste-gate A turbocharger turbine housing is like a nozzle, a smaller nozzle creates higher velocity, larger one allows more flow Ideal turbocharger would have small turbine for low end response and large turbine for high end power Simplest solution is to use small turbine with waste-gate

Turbocharger Checks : 

Turbocharger Checks Does rotating assembly rotate freely? No metal to metal contact with housing. Note that there can be considerable amount of radial and axial play in new or used turbocharger. Does wastegate operate freely and does the diaphragm hold air? It is not normally necessary to check the calibration unless it has been disassembled or damaged.

Preventive Maintenance : 

Preventive Maintenance Run the engine at idle or no load for a period of time before shutting down to prevent coking and sludging Clean air and good oil are essential for long turbocharger life

Waste-gate Calibration : 

Waste-gate Calibration Install dial indicator on rod and pressure supply with gauge on boost line 15psi max Read pressure that moves rod 1mm (.039in) D1105T 430±15 mmHg (8.3±0.3 psi) V1505T 430±15 mmHg (8.3±0.3 psi) V2003T 450±15 mmHg (8.7±0.3 psi) V3300T 530±15 mmHg (10.2±0.3 psi) Note that boost pressure on running engine will be lower because exhaust pressure force also pushes on poppet

Troubleshooting : 

Troubleshooting Black Smoke/Low Power Look for dirty air cleaner, blocked ducting to turbocharger Look for large air leaks in inlet ducting from turbocharger Check to see if turbocharger rotor rotates freely, contact will reduce air flow Stuck open wastegate

Troubleshooting : 

Troubleshooting Blue Smoke/Oil Consumption: Look for ring or valve guide problems first. Some leakage at idle is normal because seal is not positive, restricted air cleaner, high blowby can contribute. Oil drain blocked Wheel contact with housing will destroy the seals and cause leakage so look for primary cause of damage

Troubleshooting : 

Troubleshooting Noise Turbochargers make noise, a low pitch one per rev noise and a high pitch 6 per rev noise. Wheel contact with housing or foreign object damage will generate significant noise

Slide 36: 

FOD

NCR : 

NCR

Turbocharger Damage : 

Turbocharger Damage NCR: No Cause for Removal FOD: Foreign Object Damage Lubrication Related Problems Temperature Extremes Materials & Workmanship

Foreign Object Damage : 

Foreign Object Damage Hard materials will break off blade tips Soft materials such as shop rags or rubber pieces will bend back blades Abrasives will sandblast and wear away blade surfaces

Lubrication Problems : 

Lubrication Problems Abrasive material Foreign material Oil diluted with fuel Degraded oil Coking/Sludging

Temperature Extremes : 

Temperature Extremes Fuel injection problems or restricted air intake can cause temperature problems Black Smoke equals High Temperature Turbine housing warps or scales

Repeat Damage : 

Repeat Damage Three leading causes of turbocharger damage have high likelihood of resulting in repeat damage Whatever caused original foreign object damage may still be in ducting Same goes for lubrication and temperature related problems

Turbocharger Replacement : 

Turbocharger Replacement Use care in reinstalling as dirt can get into oil passages. Make sure that gasket sealant does not enter the oil passages Squirt oil into the oil inlet on the turbocharger and spin the rotor to make sure oil gets everywhere inside.