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Air Intake and Exhaust

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Air Intake and Exhaust

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    1. Air Intake and Exhaust

    7. Air Cleaner System

    8. Air Intake Systems Air Cleaner Styles (Kubota / After-market) Plastic / Steel / Pre-cleaners Single / Dual Element / Minders AC Styles - What is the determining factors of selection Cost / Weight / Type of Service Page 5-2 - SOS / Samples After-market and KUBOTA AC Styles - What is the determining factors of selection Cost / Weight / Type of Service Page 5-2 - SOS / Samples After-market and KUBOTA

    9. Air Cleaner System

    10. Air Cleaner System

    11. Air Cleaner System

    13. Air Cleaner System

    14. Air Intake Systems Air Cleaner Location / Mounting Intake Air Temperature Figures on Page 5-3 Illustrate Temps + 10 degrees above amibient De-rate Chart Serviceability (KEANET) Dimensions Vibration & Noise (1 & 2cyl Pulses)Figures on Page 5-3 Illustrate Temps + 10 degrees above amibient De-rate Chart Serviceability (KEANET) Dimensions Vibration & Noise (1 & 2cyl Pulses)

    16. Air Intake Restriction

    17. 10. Exhaust back Pressure Check exhaust system has no excessive back pressure? Performance with muffler removed?

    18. Exhaust Systems Calculations / Measurements Calculating Back Pressure Vibration Back Pressure Calculations (Page 6-2) Back Pressure is a function of: Gas Flow (Volume) Gas Temp Piping Length (Shorter is better) Piping Configuration - Friction Coefficient (Straighter the better) Muffler Resistance Vibration / Safety i.e Direction of exhaust (re-circ) and shielding (burn) Back Pressure Calculations (Page 6-2) Back Pressure is a function of: Gas Flow (Volume) Gas Temp Piping Length (Shorter is better) Piping Configuration - Friction Coefficient (Straighter the better) Muffler Resistance Vibration / Safety i.e Direction of exhaust (re-circ) and shielding (burn)

    19. Turbochargers

    20. 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

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

    22. 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

    23. 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

    24. Turbocharger Altitude 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.

    25. Turbocharger Air Flow

    26. Turbocharger Oil Flow

    27. Turbocharger Bearings & Seals

    28. 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

    29. 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

    30. 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.

    31. 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

    32. 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

    33. 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

    34. 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

    35. 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

    37. NCR

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

    39. 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

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

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

    42. 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

    43. 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.

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