SERVICE DATA

SERVICE DATA
SPECIFICATIONS
AIR CLEANER
Engine model PF6 PF6T PF6TA PF6TB
Type Cyclone
Element Paper element (Dry) or Metallic element Paper element (Dry)

TURBOCHARGER
Engine model PF6 PF6T PF6TA PF6TB
Model and (Type) — T51 (Type I) T51 (Type I), T51 (Type II)
External dimensions
(Length x Width x Height) 220 x 209.5 x 178 (8.66 x 8.25 x 7.01)
mm (in)
Max. permissible continuous
105,000
speed rpm
Direction of rotation Counterclockwise as viewed from the exhaust turbine side
Air volume kg/min (lb/min) 21 (46) 22.8 (50.3)
Compression ratio 3.2

NOTE
Type I: No O-ring on back plate
Type II: O-ring provided on back plate
Refer to the illustration on page IE-3-2.

INTERCOOLER
Engine model PF6 PF6T PF6TA PF6TB
Type — Air to air
Intercooler — Corrugated fin

EXHAUST BRAKE
Engine model PF6 PF6T PF6TA PF6TB
Type Cylinder type
Operating method Air type
Exhaust shutter type Type II Type I

IE-1-1
 SERVICE DATA

SERVICE DATA
TURBOCHARGER
Unit: mm (in)
Item Maintenance standard Service limit Remarks
0.025 - 0.080
Play in shaft axial direction —
(0.0010 - 0.0031)

Inside diameter of center Bearing part — 20.19 (0.7949)

housing Piston ring part — 20.93 (0.8240)

Outside diameter of turbine Journal part — 12.99 (0.5114)

wheel shaft Piston ring part — 17.48 (0.6882)
Outside diameter of turbine wheel shaft hub — 19.89 (0.7831)
Piston ring groove width of shaft — 1.74 (0.0685)
Runout of shaft 0.01 (0.0004) —
Inside diameter of back plate — 17.49 (0.6886)
Thrust collar groove width — 4.44 (0.1748)
Inside diameter of thrust collar — 7.95 (0.3130)
Outside diameter of thrust spacer — 17.06 (0.6717)
Inside diameter of thrust spacer — 7.95 (0.3130)
Piston ring groove width of thrust spacer — 1.77 (0.0697)
Thrust bearing thickness — 4.36 (0.1717)
Outside diameter of journal bearing — 20.07 (0.7902)
Inside diameter of journal bearing — 13.04 (0.5134)
Compressor wheel inside diameter — 7.94 (0.3126)

INTERCOOLER
Unit: kPa {kgf/cm2, psi}
Item Maintenance standard Service limit Remarks
Intercooler check pressure (air) 196 {2.0, 28} —

EXHAUST BRAKE
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Air intake shutter When compressed to
94.1 {9.6, 21.2} —
side Spring tension 105 mm (4.13 in)
Air cylinder
Exhaust shutter N {kgf, lbf} When compressed to
77.5 {7.9, 17.4} —
side 113.2 mm (4.46 in)

Valve movement in More than

Type I —
the axial direction 0.7 (0.028)
when closing the More than
valve Type II —
Exhaust 0.5 (0.020)
shutter 0.1 - 0.4
One side —
Clearance between (0.004 - 0.016)
valve and body 0.2 - 0.5
Both sides —
(0.008 - 0.020)
More than
Clearance between air cylinder shaft and clevis —
1.0 (0.04)

IE-1-2
 SERVICE DATA

TIGHTENING TORQUE
TURBOCHARGER
Unit: Nzm {kgfzm, ftzlbf}
Item Tightening torque
Oil inlet adapter mounting bolt 21 - 26 {2.1 - 2.7, 15 - 20}
Oil drain pipe mounting bolt 21 - 26 {2.1 - 2.7, 15 - 20}
Thrust bearing mounting screw 3.4 - 3.9 {0.35 - 0.40, 2.5 - 2.9}
Back plate and center housing mounting bolt 10.2 - 11.9 {1.04 - 1.21, 7.5 - 8.8}
Compressor wheel mounting nut 3.6 - 4.7 {0.37 - 0.48, 2.7 - 3.5} → Tighten (120°)
Clamp mounting bolt 9.0 - 11.3 {0.92 - 1.15, 6.7 - 8.3}
Turbine housing and center housing mounting V-band lock nut 17.0 {1.73, 12.5} → Loosen → 13.7 {1.40, 10.1}
Turbocharger assembly mounting bolt 34 - 44 {3.5 - 4.5, 25 - 33}

EXHAUST BRAKE
Unit: Nzm {kgfzm, ftzlbf}
Item Tightening torque
Air cylinder mounting nut Exhaust shutter side 21 - 25 {2.1 - 2.6, 15 - 19}
Air cylinder mounting bolt Air intake shutter side 36 - 50 {3.7 - 5.1, 27 - 37}
Air cylinder cover mounting bolt 10 - 16 {1.0 - 1.6, 7 - 12}
Air cylinder shaft nut 10 - 16 {1.0 - 1.6, 7 - 12}
Exhaust shutter shaft nut 10 - 16 {1.0 - 1.6, 7 - 12}
Exhaust shutter shaft cover mounting nut 21 - 25 {2.1 - 2.6, 15 - 19}
Lever mounting nut (Exhaust shutter only) 10 - 16 {1.0 - 1.6, 7 - 12}
Stopper bolt lock nut (Exhaust shutter only) 10 - 16 {1.0 - 1.6, 7 - 12}
Exhaust shutter mounting bolt 21 - 25 {2.1 - 2.6, 15 - 19}

IE-1-3
 TOOLS

TOOLS
TURBOCHARGER
Tool name and number Description Shape
Turbocharger tool kit Used when disassembling and reassembling the —
99760 96004 turbocharger.
Deep socket Used to tighten and remove the nut of the V-band.
99535 96000

EP15-061

Retaining ring plier Used when removing the retaining ring at the center hous-
99546 96000 ing.

EP15-064

T-handle Used to remove and install the impeller lock nut.

99773 96000

EP15-066

Holding fixture Used when disassembling and reassembling the rotating

99768 96009 assembly.

EP15-099

Piston ring guide Used when inserting the piston ring to the turbine wheel.
99763 96000

EP15-056

Pick Used when fitting the piston ring of the shaft to the center
99767 96003 housing.

EP15-062

IE-2-1
 TURBOCHARGER

TURBOCHARGER
CONSTRUCTION

WIE001A

REMOVAL

WARNING
• To avoid being burned, do not touch the exhaust pipe,
turbocharger and muffler while the engine is running
or immediately thereafter. Check that the engine has
cooled before starting work.

1. Remove the air intake duct and shield plate.

2. Remove the exhaust brake assembly and exhaust connec-
tor.
3. Remove the oil inlet tube and oil inlet adapter.
4. Remove the oil outlet pipe.
5. Remove the air intake hose and intake housing.
6. Remove the turbocharger assembly.

IE-3-1
 TURBOCHARGER

INSPECTION BEFORE DISASSEMBLY

Place the turbocharger on a level surface, and turn the com-
pressor wheel with finger tip to determine whether it operates
smoothly. Then use the following procedure to measure both
axial play.

Measuring play in the axial direction

The purpose of this procedure is to determine whether it is
necessary to replace or repair the thrust bearing and/or rotating
assembly of the center housing rotating assembly.
1. Set the dial gauge to the magnet base at the turbine wheel
end of the turbocharger.
2. Move the turbine wheel axially back and forth by hand.
(being careful not to rock turbine wheel)
3. Measure the play in the axial direction and record the
results. EIE5-003
NOTE
• When measuring the axial play, do not turn the turbine
wheel as this will cause the measurement error to
become large.
Unit: mm (in)
Maintenance standard Service limit
0.025 - 0.080 (0.0010 - 0.0031) —

Key point of disassembly

Prior to starting disassembly, spread a piece of clean oil paper
or cardboard on the work bench and make matching marks at
the connection sections of the turbine housing, center housing,
and compressor housing so that there will be no mistakes
during reassembly.
Since the turbocharger is a precision device, disassemble it with
the utmost care.

EIE5-004

3 Turbine housing
j
Remove the turbine housing. Loosen the lock nut as required to
disengage the V-band coupling from the flange of the turbine
housing and center housing.
NOTE
• If the turbine housing, center housing have stuck, apply
‘‘Thread release’’ oil to the register dia., then remove it,
being careful not to damage the turbine wheel.
If necessary, tap the turbine housing with a wooden
hammer. EIE5004A

IE-3-3
 TURBOCHARGER

5 Compressor housing
j
Remove the compressor housing.
Loosen the compressor bolt and remove the clamp.
NOTE
• Be careful not to damage the compressor wheel.

EIE5-005

EIE5005A

NOTE
• The compressor wheel and turbine wheel are precisely
dynamically balanced and cannot be repaired. There-
fore, they must be handled with extra special care.

EIE5005B

6 Rotating assembly
j
Place Holding Fixture (99768 96009) in a vise, and set the
turbine wheel on it with the compressor wheel on it with the
turbine wheel side facing downward.

WIE003A

8 Compressor wheel
j
1. Remove the compressor wheel.
Using a T-handle (99773 96000), remove the lock nut, and
then remove the compressor wheel by hand.
NOTE
• Since bending of the turbine wheel is also related to the
life of the turbocharger, be careful not to bend it.
• Support the turbine wheel by hand while loosening the
lock nut.
EIE5006A

IE-3-4
 TURBOCHARGER

2. Remove the compressor wheel by hand.

EIE5-007

j
10 Piston ring
Remove the piston ring.
NOTE
• Once removed, the piston ring must always be replaced
with a new piston ring when reassembling.
However, since the turbine wheel can be reused, be
careful not to damage it.

EP15-028

j
12 Back plate
Remove the backplate.
Loosen the backplate bolt, remove the washer and remove the
backplate.
NOTE
• When the backplate cannot be removed by hand, tap the
center housing lightly with a wooden mallet and then
remove.

EIE5-009

j
14 Thrust spacer, j 15 Piston ring

Pull out the thrust spacer from center of the backplate and
remove the piston ring from the thrust spacer.
The piston ring can be removed by hand.

EIE5-011

j
17 Thrust bearing, j 18 Thrust collar

Loosen the thrust bearing bolt, then remove the thrust collar and
thrust bearing.

EIE5-010

IE-3-5
 TURBOCHARGER

j
19 Journal bearing
1. Remove the journal bearing.
NOTE
• Be careful not to damage the center housing when
removing the retainer ring.

WIE004A

2. Using retaining ring pliers (99546 96000), remove the com-

pressor wheel side retaining ring and journal bearing.
3. Using retaining ring pliers (99546 96000), remove the tur-
bine wheel side retaining ring and journal bearing.
4. Remove the two retaining rings located in the rear of the
center housing.

EIE1-063

IE-3-6
 TURBOCHARGER

NOTE
• If the measured value exceeds the maintenance stan-
dard, replace the part.
Inside diameter of center housing
Unit: mm (in)
Item Maintenance standard Service limit
Bearing part (A) — 20.19 (0.7949)
Piston ring part (B) — 20.93 (0.8240)
ER6-005A

Outside diameter of turbine wheel shaft

Unit: mm (in)
Item Maintenance standard Service limit
Journal part — 12.99 (0.5114)
Piston ring part — 17.48 (0.6882)

EP15-034

Outside diameter of turbine wheel shaft hub

Unit: mm (in)
Maintenance standard Service limit
— 19.89 (0.7831)

EP15-092

Piston ring groove width

Unit: mm (in)
Maintenance standard Service limit
— 1.74 (0.0685)

Runout of shaft
Unit: mm (in)
Maintenance standard Service limit
0.01 (0.0004) —

EP15-035

IE-3-9
 TURBOCHARGER

Inside diameter of back plate

Unit: mm (in)
Item Maintenance standard Service limit
Back plate seal bore
diameter — 17.49 (0.6886)
(measurement A)

WIE005A

Thrust collar
Unit: mm (in)
Item Maintenance standard Service limit
Groove width (A) — 4.44 (0.1748)

ER6-007

Inside diameter of thrust collar

Unit: mm (in)
Maintenance standard Service limit
— 7.95 (0.3130)

Outside diameter of thrust spacer

Unit: mm (in)
Maintenance standard Service limit
— 17.06 (0.6717)

Inside diameter of thrust spacer

Unit: mm (in)
Maintenance standard Service limit
— 7.95 (0.3130)

Piston ring groove width of thrust spacer

Unit: mm (in)
Maintenance standard Service limit
— 1.77 (0.0697)

IE-3-10
 TURBOCHARGER

Thrust bearing thickness

Unit: mm (in)
Maintenance standard Service limit
— 4.36 (0.1717)

EIE1-027

Journal bearing
Unit: mm (in)
Item Maintenance standard Service limit
Outside diameter — 20.07 (0.7902)
Inside diameter — 13.04 (0.5134)

Compressor wheel inside diameter

Unit: mm (in)
Maintenance standard Service limit
— 7.94 (0.3126)

REASSEMBLY
Preparations before reassembly
Repair light damage by polishing. Aluminum parts must be
polished with a polishing cloth using silicon carbide.
Moreover, steel parts must be polished with a polishing cloth
using polishing powder. Always replace the following parts.
Part name Quantity
Turbine V-band lock nut 1
Bolt (Compressor housing) 6
Lock nut (Compressor wheel) 1
Piston ring (Turbine wheel) 1
Bolt (Back plate) 4
Seal ring 1
Piston ring (Thrust spacer) 2
Screw (Thrust bearing) 3
Thrust bearing 1
Journal bearing 2
Retaining ring 3

IE-3-11
 TURBOCHARGER

Key point of reassembly

j
20 Retaining ring, j 19 Journal bearing

Using retaining ring pliers (99546 96000), install the retaining

rings in the rear of the center housing, then install the journal
bearing and the outer retaining ring.
j1 Journal bearing j
4 Retaining ring
j2 Retaining ring j
5 Center housing
j3 Journal bearing

EP15-044
NOTE
• Ensure that the open end of the retaining ring faces the
oil outlet and the round portion faces the journal bear-
ing.
• Be careful not to damage the center housing when
installing the retaining ring.
• Coat the inner and outer periphery of journal bearing
with engine oil.
Replace the journal bearing with a new one.

EIE1-064

j
18 Thrust collar, j17 Thrust bearing

Coat the thrust bearing pads with engine oil and then install the
thrust bearing and thrust collar into the center housing with
three screws.
j1 Screw j3 Thrust bearing
j2 Thrust collar j4 Center housing

: 3.4 - 3.9 Nzm {0.35 - 0.40 kgfzm, 2.5 - 2.9 ftzlbf}

NOTE
• All tapped holes in the TA5103 turbochargers are metric EP15-095

with a selflocking thread form.

j
15 Piston ring, j 14 Thrust spacer

1. Install the piston rings on the thrust spacer.

2. Install the thrust spacer assembly to the back plate.
NOTE
• Ensure that the open end of the turbine side piston ring
faces the oil outlet and the open end of the compressor
side piston ring faces the oil inlet.

EIE1-060

IE-3-12
 TURBOCHARGER

j
10 Piston ring
Using a piston ring guide (99763 96000), insert the piston ring
into the turbine wheel.

EIE3-050

9 Turbine wheel
j
1. Place the center housing assembly on the compressor
housing.
2. Apply a coat of engine oil to the turbine wheel journal, and
carefully insert the turbine wheel into the bore in the center
housing.
Use a pick (99767 96003) to compress the piston ring and
install it while rotating the wheel shaft.
NOTE EIE1-058
• Be careful not to scratch or break the piston ring.
• Ensure that the open end of the piston ring faces the oil
inlet.

EP15-047

8 Compressor wheel
j
• Before installing the compressor wheel, clean the parts and
check carefully the tightening surface for dust or foreign
matter.

Coat the compressor wheel mounting and screw section of

the turbine wheel and the surface of the lock nut seat with a
thin coat of seizure preventative.
Fit the compressor wheel into the turbine wheel and tighten
the lock nut temporarily.
Attach the rotating assembly to a holding fixture (99768
96009) which has been placed in a vise.

WIE003A

IE-3-13
 TURBOCHARGER

4. Using a torque wrench, tighten the lock nut temporarily.

: 3.6 - 4.7 Nzm {0.37 - 0.48 kgfzm, 2.7 - 3.5 ftzlbf}
NOTE:
• When tightening the nut, be careful not to give the
bending force to the shaft.

EP15-049

5. Tighten the lock nut completely with T-handle (99773

96000) by turning nut 120° further than the temporary
position.
NOTE:
• Keep the rated tightening torque and tightening angle.

EIE5006A

5 Compressor housing
j
Attach the compressor housing to the back plate by properly
aligning their marks, then tighten the bolts with the clamps.
: 9.0 - 11.3 Nzm {0.92 - 1.15 kgfzm, 6.7 - 8.3 ftzlbf}

EIE5005B

3 Turbine housing
j
1. Install the turbine housing to the center housing by aligning
the alignment marks. Using a deep socket (99535 96000),
tighten the V-band.
: 1st ... 17.0 Nzm {1.73 kgfzm, 12.5 ftzlbf}
2nd ... Loosen
3rd ... 13.7 Nzm {1.4 kgfzm, 10.1 ftzlbf}

EIE5-004

2. Compressor housing assembly angle (View from the air

intake side)
Engine model Value α
PF6T 292°
PF6TA, PF6TB 180°

WIE006A

IE-3-14
 TURBOCHARGER

INSTALLATION

1. Install the turbocharger assembly on the exhaust manifold

using a gasket.
: 34 - 44 Nzm {3.5 - 4.5 kgfzm, 25 - 33 ftzlbf}
NOTE
• Mounting nuts are heat-resistant types. Do not confuse
them with conventional nuts.

2. Install the exhaust connector using a gasket and spacer to

the turbocharger assembly.
: 34 - 44 Nzm {3.5 - 4.5 kgfzm, 25 - 33 ftzlbf}
NOTE
• Mounting nuts are heat-resistant types. Do not confuse
them with conventional nuts.
3. Install the oil pipe.
: 21 - 26 Nzm {2.1 - 2.7 kgfzm, 15 - 20 ftzlbf}
4. Connect the oil drain pipe to the turbocharger.
: 21 - 26 Nzm {2.1 - 2.7 kgfzm, 15 - 20 ftzlbf}
5. Install the turbocharger shield plate, shield bracket and
exhaust connector shield plate.
6. Connect the air intake duct and exhaust pipe using a gasket.
7. After installing the turbocharger assembly, crank the engine
using the sub-starter switch. Crank for approximately 10 to
20 seconds while pulling the engine stop lever. Crank the
engine until the oil pressure gauge activates, since oil is not
distributed to the oil line.

IE-3-15
 INTERCOOLER

INTERCOOLER
CONSTRUCTION

WIE007A

INSPECTION

Remove the intercooler. If mud, insects, etc. are attached to the front surface of the intercooler core,
remove them using a copper wire or the like exercising care not to damage the tube.
Water pressure test
Seal one of the air intakes on the intercooler with a lid and connect a hose to the other intake. Then
submerge the intercooler under water in a tank and blow compressed air through the hose to the specified
pressure to check for air leakage.
Intercooler check pressure (air): 196 kPa {2.0 kgf/cm2, 28
psi}

IE-4-1
 EXHAUST BRAKE

EXHAUST BRAKE
CONSTRUCTION
EXHAUST SHUTTER
Type I

WIE009A

IE-6-1
 EXHAUST BRAKE

AIR CYLINDER

WIE013A

Disassembly sequence (Reassembly sequence is the reverse of disassembly.)

j
1 Snap j
7 O-ring j
13 Guide
j
2 Pin j
8 Retainer j
14 Washer (Exhaust shutter side only)
j
3 Clevis j
9 Packing j
15 Protector
j
4 Dust seal j
10 Wear ring j
16 Shaft
j
5 Cover j
11 Plate j
17 Cylinder body
.j
6 Cover j
12 Spring

Marks ‘‘.’’ and ‘‘>’’ indicate that the key points of operation are explained in the text.

EXHAUST BRAKE AIR CYLINDER

Key point of disassembly
6 Cover
j
Remove the cover and O-ring.
NOTE
• Be careful when removing the cover - the shaft assem-
bly may jump out due to spring tension.

IE-6-6
 EXHAUST BRAKE

INSPECTION

Clean all disassembled parts in cleaning solvent. Check for

scratches, cracks or damage and replace faulty parts.
If measurement indicates that the service limit has ex-
ceeded, repair or replace faulty parts.
AIR CYLINDER
Spring tension
Unit: N {kgf, lbf}
Maintenance
Item Service limit Remarks
standard
Air intake shutter When compressed to
94.1 {9.6, 21.2} —
side 105 mm (4.13 in)
Exhaust shutter When compressed to
77.5 {7.9, 17.4} —
side 113.2 mm (4.46 in)

EXHAUST SHUTTER
Valve movement in the axial direction when closing
the valve
Unit: mm (in)
Item Maintenance standard Service limit
PF6T, PF6TA, B Type I More than 0.7 (0.028) —
PF6 Type II More than 0.5 (0.020) —

Clearance between valve and body

Unit: mm (in)
Item Maintenance standard Service limit
0.1 - 0.4 (0.004 -
One side —
0.016)
0.2 - 0.5 (0.008 -
Both sides —
0.020)

REASSEMBLY

EXHAUST SHUTTER
Key point of reassembly
j
10 j
11 j
12 j
13 Seal ring
Install the seal rings so that rings with different shapes are
placed next to each other.

WIE014A

IE-6-7
 EXHAUST BRAKE

- MEMO -

EE-6-9