THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF

M & W OR IT’S SUCCESSORS. M & W AND IT’S SUCCESSORS

ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS,

AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

Service Manual

Servic

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ual

Turbochargers

MW-S-TURBO

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Form 1732

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Service Instructions INSTALLATION, OPERATION

AND

MAINTENANCE

M 6. W TURBOCHARGERS

For Diesel

Tractors

Ma1N GEAR COMPANY ANCHOR, ILLINOIS

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M & W TURBOCHARGERS

TABLE OF CONTENTS

Title Page

SERVICE IN STR U CTI 0 N S ________________________________ ______________________________________________________________________ 1

1. In trod u cti on _____________________________________________ . ______________________________________________________________________ 1

2. Routine Turbocharger Maintenance __________________________________________________________________________ 2

3. Installa tio n __ ____________________ __________________________ ____ _ ___ __ ____ _ __________________________ _____________________________ 4

4. Trouble Shooting __________________________________________________________________________________________________________ 4

5. Special Tools _____________________________ ._____________________________________________________________________________________ 5

6 . Disassembly _________________________________________________________________________________________________ .__________________ 5

7. Cleaning and Inspection After Disassembly ____________________________________________________________ 8

8. Reassembly ______________________ _____________________________ _ ___ __ _ _ _______________ __________________________________________ 9

9. Torque Values and Clearances __________________________________________________________________________________ 12

PARTS LIST ______________________________ .. _____________________________________________________________________________________________ 15

i

M & W TURBOCHARGERS

Service Instructions

INSTALLATION, OPERATION AND MAINTENANCE

1. INTRODUCTION. This manual provides the necessary information for routine mainte­nance, trouble shooting, and complete rebuilding of M & W Turbochargers (figure 1).

a. Design.

M & W turbochargers are backed by more than a half century of experience and the integrity of a leading designer-producer of automotive and aircraft parts. These units combine light weight, compact design, and ease of installation with rugged construction to enable them to meet the most severe operating conditions. The advanced, yet simple design, and the rigid production stand­ards assure long turbocharger life and peak oper­ating efficiency with proper maintenance.

b. Principles of operation.

The lightweight, compact M & W· turbocharger is designed to operate efficiently at high rotative speeds. It consists of a precision-balanced rotat­ing group with a turbine wheel on one end and a centrifugal impeller on the other, each wheel en­closed in a housing.

As shown in figure 2, the hot engine exhaust gases are directed against the· turbine wheel, spinning the turbine wheel and shaft at a high rate of speed. The impeller in the compressor portion of the turbocharger draws air in, passing it through a diffuser radially outward, to build up air pressure in the intake manifold of the engine. This increases the weight of air available to the engine and enables the engine to burn more fuel, resulting in greater horsepower output than is possible with a naturally aspirated engine of the same size. The excess air provides improved cylinder scavenging, resulting in better fuel econ­omy and lower exhaust temperatures.

Under heavy load or lugging operation, the turbocharger speed automatically increases, pro­viding more air to the engine to meet the demand. When engine load is light, the speed of the turbo­charger decreases.

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Since the turbocharger is not mechanically coupled to the engine, but is driven by the ex­haust energy that is normally wasted, no engine power is consumed. The effect of the exhaust manifold back pressure is more than offset by the discharge of air from the compressor.

The turbocharger is provided with a semi­floating sleeve bearing which is lubricated with oil from the engine lubrication system. Piston-

TURBINE

Figure 2. Turbocharger Operation Diagram •.

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M & W TURBOCHARGERS

CAUTION

Do not rest the assembly on the blades of the turbine wheel.

(5) Install a short length of V2-inch pipe in one of the bearing housing oil drain holes, and sup­port the turbocharger with a vise as shown in figure 4. Remove the six bolts that secure the compressor housing to the turbocharger bearing housing; remove the compressor hQusing and gasket.

(6) If the impeller (figure 5) requires cleaning, use a nylon-bristle brush and a solvent such as diesel fuel or kerosene to remove accumulated dirt. Thoroughly· clean the impeller and the compressor housing. Failure to remove all dirt may result in more severe disruption of balance than that which existed prior to cleaning.

CAUTION

Never use caustic solution or other cleaner that may attack metal. Nev­er use a wire brush that could score highly finished parts.

(7) Use two clamps, as shown in figure 5, to overcome the tension of the spring ring and hold the turbine shield against the bearing hous­ing.

(8) Attach a dial indicator to the bearing hous­ing so that the indicator point is resting on the impeller nut. Push up on the turbine wheel, as

Figure 4. Turbocharger Mounted in Vise.

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'.~4· •• __ DIAl INDICATOR

Figure 5. Measuring Turbine Shaft End Play.

shown in figure 5, to measure the shaft end play. The allowable shaft end play is 0.005 to 0.008 inch. If the shaft end play is excessive, the tur­bocharger should be rebuilt.

(9) Position the dial indicator so that the in­dicator point is resting on a flat of the impeller nut and set at zero. Push the impeller from side to side, as shown in figure 6, to determine the shaft radial play. Rotate the shaft slightly to get

DIAl INDICATOR

Figure 6. Measuring Shaft Radial Play.

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Trouble

Smoking engine exhaust, loss of engine power, low boost pressure.

Noisy rotating assembly.

Excessive vibration.

Excess oil in intake manifold or exhaust stack.

Turbo speed low, power low, clean exhaust.

M & W TURBOCHARGERS

TROUBLE SHOOTING CHART

Probable Cause

Dirty air cleaner, undersize air cleaner.

Restricted intake manifold or piping.

Foreign matter or dirt accumu­lation on impeller.

Interference or binding in rotat­ing assembly.

Damaged impeller or turbine wheel.

Excessive oil leakage from seals.

Damaged bearing or other com­ponents causing rotating assem­bly to rub against housing.

Foreign matter or carbon ac­cumulation obstructing rotation.

Damaged bearing.

Damaged impeller or turbine blades.

Restricted induction system.

Oil carry-over from air cleaner.

Excessive oil leakage from seals.

Insufficient fuel supply to engine.

Leaking intake or exauhst mani­fold connections.

Back pressure on turbo exhaust too high.

Remedy

Clean or replace air cleaner as required.

Remove restriction.

Clean impeller (see par. 2b).

Disassemble unit.

Disassemble unit.

Disassemble unit, replace seals.

Disassemble unit, replace defective components.

Clean and inspect unit (see par. 2), disassemble if required.

Disassemble unit, replace bearing.

Disassemble unit, replace defective parts.

Inspect and clean (see par. 2a).

Service or replace air cleaner.

Disassemble unit, replace seals.

Clean or reset fuel pump.

Tighten all connections and replace gaskets where required.

Reduce restriction in exhaust stack .

6. DISASSEMBLY •

5

NOTE

Disassemble the turbocharger oply in a clean, dust-free location, using clean teols and equipment. Avoid contact with dust or grit that could Score the highly machined parts and result in premature failure of the unit.

a. Remove the nut from the. housing clamp that secures the turbine housing to the bearing

M & W TURBOCHARGERS

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Figure 7, Turbocharger, Exploded View.

housing as shown in figure 3; remove the clamp, turbine housing, and gasket.

b. Install a short length of 1f2-inch pipe in one of the three oil drain holes of the bearing hous­ing. Support in a horizontal position in a vise as shown in figure 4.

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c. Remove the six bolts (24, fig. 7) that secure the compressor housing (26) to the bearing hous­ing (11); remove the compressor housing and gas­ket.

d. Hold the blades of the turbine with a cloth and remove the self-locking nut (22) (left-hand