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Holset HE201W/211W/221WService Repair Manual
Copyright 2010, Cummins Turbo Technologies Ltd. All rights reserved.VGT, Command Valve and Super MWE are trade marks of Cummins Turbo Technologies Ltd.Holset and the Holset Logo are registered trade marks of Cummins Turbo Technologies Ltd.Cummins and the Cummins logo are registered trade marks of Cummins Inc.
WARNING
Turbochargers can be hazardous when notused as specified by the manufacturer. Toprevent damage and personal injury:
Always use the turbocharger part number specifiedby the engine manufacturer.Use only in applications approved by the enginemanufacturer.Do not touch before checking surface temperatures.Do not work on a running turbocharger or engine.Do not modify the turbocharger in any way.Disassemble and re-assemble using the enginemanufacturer’s instructions.Use only approved spare parts.For advice on the safe use of turbochargerscontact www.holset.com
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Foreword
ForewordThis publication was written to assist with turbocharger installation, maintenance and overhaul. It is not awarranty of any kind expressed or implied.
The specifications and procedures in this manual are based on information in effect at the time of publication.Holset Service reserves the right to make any changes at any time without obligation. If differences are found
between your turbocharger and the information in this manual, contact your local Holset approved agent.
The latest technology and the highest quality standards are used in the manufacture of Holset Turbochargers.When replacement parts are needed, we recommend using only genuine Holset parts.
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Table of Contents
Table of Contents1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:1
About the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:1
How to Use the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:1
How to Order Holset Original Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:1
Description and Operation of Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:2
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:2
Introduction to Wastegate Turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:2
Notes, Cautions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:3
Installation Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:5
Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:6
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:7
2: Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2:1Turbocharger Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2:1
Dataplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2:1
Center Housing Rotating Assembly (CHRA) (2) . . . . . . . . . . . . . . . . . . . . . . . . 2:1Installation Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2:2
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2:4
Component List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2:6
Purchasable Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2:8
3: Troubleshooting and Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3:1Fault Finding chart - All Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3:1
4: Component Testing and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 4:1Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4:1
On Engine Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4:2Bearing Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4:6
Turbine and Compressor Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4:7
Cleaning of Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4:11
Reassembly of Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4:13
Wastegate Actuator Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4:16
Actuator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4:18
Wastegate Mechanism Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4:19
Wastegate Actuator Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4:21
Actuator Bracket Removal and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4:29
5: Turbocharger Service and Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5:1Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5:1
D i s a s s e m b l y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 : 2
Component Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5:6
Inspection and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5:8
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5:13
6: Service Data Sheets HE Range Service Data Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6:1
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1:1
Introduction
About the ManualThe procedures in this manual were developed to instruct in the correct overhaul of the designated Holsetturbocharger range for optimum performance and minimum maintenance operation.
How to Use the ManualThe manual is split into sections designed to provide service information in a logical sequence. The manualcontains links to help the user navigate between relevant sections. Users who are unfamilier with navigating inPDF documents are refered to Navigating in PDF documents in the Adobe¨ Acrobat¨ Readerª help file.
Contents is an interactive page with links to all the sections. It can be accessed from any page in the manual by clicking this icon.
Section 1 defines the layout of the manual, introduces the reader to the operation of the turbocharger and presents important installation guidelines.
Sections 2, 3 and 4 concentrate on Turbocharger Component Identification, Troubleshooting and Diagnosis, Component Testing and Replacement.
Section 5 identifies the Service and Overhaul procedures to be followed in the unlikley event of amajor turbocharger malfunction.
Section 6 quantifies build data to ensure the turbocharger will continue to operate to Holset Service standard on completion of overhaul.
Manual sections 1 to 5 where applicable, appear as a self extracting compressed file which is organisedaccording to the steps needed to most easily and correctly maintain the operation of the turbocharger. Usersare required to download this file to hard disk. Section 6 has its own file identity and resides at www.holset.co.uk. so that Holset can update the Service Data as changes occur. The links between manual and service dataare active only when the user is connected to the Internet.
Chapter 6 has an expiry date to encourage users to discard outdated saved or printed versions and alwaysaccess the latest information available at www.holset.co.uk.
When using the manual on-line this icon will link to HolsetÕs website to help find your nearest agent for advice and how to order Holset original parts.
How to Order Holset Original PartsTo make sure of optimum performance, certain items must be discarded during disassembly and replaced withnew for re-assembly. These items are indicated in the Service and Overhaul section with the use of a * symbol.All items showing a * are available in a basic overhaul kit.
To get the correct parts for your turbocharger, refer to the Ôcomponent identificationÕsection of this manual tohelp you find the following information:
1) Refer to the exploded view and component list to define the major components to be replaced. 2) Refer to the turbochargerÕs dataplate which will be found on the compressor cover or wastegate
actuator to define the identifying information about your turbocharger build standard. 3) Contact your local Holset agent with componant identification nos. and dataplate assembly no., serial
no. and turbocharger type. 4) With this information, your local agent can provide you with the optimum kit of parts for re-assembling
your turbocharger for continued long life operation.
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Introduction
Description and Operation of Turbocharger
General Information A turbocharger is a mechanical device which uses the engineÕs exhaust gases to force more air into the enginecylinders. Hot exhaust gas energy is used to turn a turbine wheel and shaft. At the other end of the shaft is thecompressor impeller (or compressor wheel), which draws in air and forces it into the engine cylinders.
Supplying increased air mass flow to the engine provides improved engine performance, lower exhaust smoke
density, improved operating economy and altitude compensation. The turbocharger has proven to be one of themost beneficial devices for improving engine performance. It performs its job very well, as long as it is properlycared for.
Introduction to Wastegate Turbochargers The need for wastegated turbochargersA standard turbocharger can be perfectly matched to only one particular engine condition, eg maximum torquespeed or maximum load speed. At this engine speed, the turbocharger supplies the optimum mass of air togive the required air/fuel ratio. At other speeds the air/fuel ratio cannot be held at the optimum hence fuelconsumption and emission levels worsen.
Engine emission legislations have forced manufacturers to improve their engine efficiencies, particularly at low
speeds where low air/fuel ratios cause high smoke levels.The Holset integral wastegate turbocharger is a cost effective solution to this problem and for a small increasein complexity, a simple variable flow turbine housing has been achieved.
Integral wastegate turbochargers have been available for passenger cars for many years. Holset hasdeveloped such a turbocharger with components designed for extended life equal to that of standardcommercial vehicle turbochargers.
The importance of correctly servicing the turbochargerA turbocharger requires accurate assembly at point of manufacture. It is very important to adhere to settinglimits when servicing the turbocharger, as failure to do so could result in turbocharger or engine failure.
Effects of wrong matchPossible consequences if turbocharger boost pressure is too low:-
• Engine runs fuel rich • Fuel consumption increase
• Exhaust temperature increase • Smoke levels increase
• Hydrocarbon levels increase • Risks of failing emissions tests
• High cylinder temperature risksdamage to engine pistons
Possible consequences if turbocharger boost pressure is too high:-
• Engine runs fuel weak (lean) • Nitrous oxide levels increase
• Excessive boost overspeeds • Turbocharger bearing failure and turbocharger wheel fatigue problems
• Increased cylinder pressure risks damage • Intercooler load increases causing engine to engine head gasket, pistons and valves to overheat, risking piston damage
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Introduction
Notes, Cautions and Warnings
Notices, Cautions and Warnings are used in this manual to emphasise important or criticalinstructions.
Notice Information which is essential to highlight.
Caution Maintanence or Service procedures which if not strictly followed, will result in damage or destruction of
turbocharger.
Warning Maintanence or Service procedures which if not correctly followed will result in personal injury or loss of life.
WARNING
Some parts are manufactured in fluoroelastomers (eg Viton) or similar that require special treatment
in case of repair and service after fire.
WARNING
Turbocharger surface temperature during operation can achieve 700°C (1300°F).
WARNING
Designated range of turbochargers weighs up to 4.75 kg (10.5 lb) and is fitted with external parts thatare sensitive to manual handling.
CAUTION
This turbocharger was manufactured using high speed ‘core balance’ process and will not have
co-relation marks on rotor parts. A core balanced turbocharger MUST be core balanced on rebuild.
If you are in any doubt regarding balancing process, please contact your local Holset agent forassistance. Operating a turbocharger with balance levels greater than published limits could cause
turbocharger or engine failure.
CAUTION
Always check actuator and wastegate mechanism function before proceeding with turbocharger
disassembly. Unless wastegate actuator is to be renewed, leave in position as part of housingassembly while servicing turbocharger. Never adjust end link of assembled wastegate turbocharger.
End links are set to precise limits to maintain emissions and performance specifications.
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Introduction
Notes, Cautions and Warnings
NOTICEMany turbochargers are returned that are no fault found. Before assuming turbocharger is not
performing to specification always refer to engine diagnostic system and troubleshooting diagnostic
procedures of this manual.
NOTICEWhere it is necessary to dispose of components or whole turbochargers, an environmentallyresponsible process such as recycling should be used, with due regard to local laws.
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Introduction
Installation Data1. Many turbochargers are returned that are no fault found. Before assuming the turbocharger is not
performing to specification always refer to the engine diagnostic system and the fault finding chart of thismanual to make all the recommended health checks.
2. It is important that intake and exhaust systems are fitted in accordance with the recommendations ofthe Equipment and Engine manufacturers. It is important not to overload the turbocharger by externalattachments or forces.
3. The air filter must remove particles greater than 5 µm at an efficiency of 95% and be of sufficient capacityto match the air consumption of the engine. Recommended filters should always be used with a pressuredrop indicator. Intake systems must be capable of withstanding depressions up to 6.9 kPa (1.0 lbf/in2).
4. Hose and clip connections of the intake manifold system must be tightened to the values specified by theEquipment and Engine manufacturers to withstand turbocharger pressure ratio.
5. Exhaust systems must be capable of operating at exhaust back pressures of up to 10 kPa (1.5 lbf/in2).This limit is increased to 13.4 kPa (2.0 lbf/in2) if a catalytic converter is fitted. Exhaust brake applicationsare permitted to operate at a continuously rated pressure up to 450 kPa (65.3 lbf/in 2) back pressure.
6. Oil should be filtered to 10µm with efficiency of 60% TWA (Time Weighted Average) /20 µm withefficiency of 85% TWA. Efficiency assessed to ISO Standard 16889:1999 (was 4572/SAE J 1858). Alwaysuse filters recommended by engine manufacturer.
7. The oil quality must be as specified by the Engine manufacturer and will be a minimum API SE - CD(MIL - L - 2104C) specification. Recommended oil change intervals are 5000 to 10,000 km (250 to 500h)depending on duty. Improved life can be obtained by using super high performance diesel (SHPD) oils,particularly in industrial applications which use extended oil drain periods.
8. Normal oil temperature is 95+/-5¡C (203+/-9¡F). It should not exceed 120¡C (248¡F) under any operatingcondition.
9. Any pre-lube oil must be clean and meet the minimum CD classification.
10. The orientation of turbine housing, bearing housing and compressor cover is fixed according toapplication. During installation, do not attempt to rotate these components.
11. Oil return pipes are permitted to decline at an overall angle of not less than 30 degrees below horizontal.All turbocharger applications require a pipe of internal diameter greater than 14 mm which has integratedconnectors. To ensure oil drains into the engine under all operating conditions, the return connection
into the engine sump must not be submerged and the outlet flange of the turbocharger must be 50 mmabove the maximum oil level of the engine sump pan.
12. Crankcase pressure should be limited to 0.8 kPa (0.12 lbf/in2). This limit applies at all engine idlingconditions between low and high idle speeds, including overrun. Pressure above this level should bereferred for further evaluation. Closed crankcase ventilation (CCV) systems are known to operate atelevated pressure and all applications must be referred for approval.
13. Oil pressure of 150 kPa (20 lbf/in2) must show at the turbocharger oil inlet within 4 seconds of enginefiring to prevent damage to turbocharger bearing system. A flexible supply pipe is recommended.
14. The minimum oil pressure when the engine is on load must be 210 kPa (30 lbf/in2). Recommended fullload rated speed operating pressure is 350 kPa (50 lbf/in2) although 500 kPa (72 lbf/in2) is permittedduring cold start up. Under idling conditions pressure should not fall below 80 kPa (11.5 lbf/in2).
15. Recommended oil flows for the turbochargers are 0.4 litre/min at idle and 1.4 litre/min at maximum engine
speed.16. Do not use liquid gasket substances or thread sealant as any excess can enter the turbocharger oil
system to obstruct flow.
17. Recommended coolant flows for the turbochargers are 2 litre/min at idle and 7 - 10 litre/min abovemaximum torque speed.
Note:
100 kPa = 1 bar (14.5037 lbf/in2 =psi).
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Introduction
Installation Checklist1. Always understand why the original turbocharger needs replacing before fitting another unit.
2. Check the turbocharger dataplate to ensure the Part No. is correct for the engine/application.
3. Check the engine exhaust, intake and aftercooler systems are clean and without obstruction i.e. free fromoil, gasket pieces, dust/dirt/carbon or foreign objects.
4. Replace the oil and air filters using replacement parts specified by the equipment manufacturer.
5. Change the engine oil using the type specified by the engine manufacturer.
6. Check that the turbocharger oil inlet and drain pipes and connectors are clean, free from obstruction andwill not leak under pressure.
7. Check that the coolant pipes of water cooled bearing housing applications and connectors are clean, freefrom obstruction and will not leak under pressure.
8. To pre-lube the turbocharger bearings, pour some clean engine oil into the oil inlet and rotate theturbocharger rotor assembly by hand.
9. Check that the exhaust manifold flange is flat and undamaged. Mount the turbocharger on the flange andcheck that the turbine inlet gasket fits properly without obstructing the gas passages.
10. Assemble the air intake and boost outlet connections. Check that the connections are well made and willnot leak in use.
11. Check the exhaust system is fitted using the original mounting arrangement provided by the equipmentmanufacturer. Always re-fit any supports/brackets back in position to ensure the system is correctlysupported.
12. Assemble the exhaust system to the turbine housing outlet. Check that the gasket/connection is well madeand will not leak in use.
13. Assemble any coolant pipes and check that the connections are well made, without obstruction and willnot leak in use.
14. Assemble the turbocharger oil inlet pipe and check that the connection is clean, well made and will notleak in use.
15. Check all clamps and fasteners are correctly tightened to the torque recommended by the equipmentmanufacturer.
16. Connect the air pipe from the compressor housing/inlet manifold to the wastegate actuator ensuring thepipe bore is clean and dry before fitment.
17. Make any ECU checks recommended by the engine manufacturer.
18. Crank the engine WITHOUT firing until engine oil flows out of the turbocharger drain flange.
19. Assemble the oil drain pipe and check that the connection is well made, without obstruction and will notleak in use.
20. Start the engine and run at idle speed for approximately 1 minute so that the oil supply system is fullyoperational.
21. Accelerate the engine and check that there are no leaks/obstructions of air/oil/coolant/gas under pressure.
22. Check that no hose or connection deforms under normal operation.
23. Before switching off the engine, leave it running at idle speed for at least 1 minute to cool the turbine.
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1:7
Symbole - DeutschIn diesem Handbuch werden die folgenden Symbole verwendet, die wesentliche Funktionen hervorheben. DieSymbole haben folgende Bedeutung:
AUSBAU bzw. ZERLEGEN.
EINBAU bzw. ZUSAMMENBAU.
INSRPEKTION erforderlich.
Teil oder Baugruppe REINIGEN.
DIMENSION - oder ZEITMESSUNG.
Teil oder Baugruppe …LEN.
WERKZEUGGR…SSE wird angegeben.
ANZUG auf vorgeschriebenes Drehmoment erforderlich.
Sicherstellen, da§ die AUSWUCHTMARKEN an der Rotor-Baugruppe richtig ausgerichtet sind.
Elektrische MESSUNG DURCHF† RHREN.
Weitere Informationen an anderer Stelle bzw. in anderen HandbŸchern.
Schutzkleidung mu§ immer getragen werden.
Deutet an, da§ Teile schwer sein kšnnen.
Website-Verzeichnis mit Ihrem nŠchsten Holset-HŠndler.
Gehe zu Inhalt
Introduction
Symbols
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Symbols - EnglishThe following group of symbols have been used in this manual to help communicate the intent of theinstructions. When one of the symbols appears, it conveys the meaning defined below.
Indicates a REMOVAL or DISASSEMBLY step.
Indicates an INSTALLATION or ASSEMBLY step.
INSPECTION is required.
CLEAN the part or assembly.
PERFORM a mechanical or time MEASUREMENT.
LUBRICATE the part or assembly.
Indicates that a WRENCH or TOOL SIZE will be given.
TIGHTEN to a specific torque.
Ensure that the BALANCE MARKS on the rotor assembly are in alignment
PERFORM an electrical MEASUREMENT.
Refer to another location in this manual or another publication for additional information.
Please wear protective clothing at all times.
Indicates components may be heavy.
Website access to find your nearest Holset Agent.
Go to contents
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1:9
Simbolos - Espa–olLos simbolos siguientes son usados en estes manual para clarificar el proceso de las instrucciones. Cuadoaparece uno de estos simbolos, su significado se espcifica en la parte inferior.
Indica un paso de REMOCION o DESMONTAJE.
Indica un paso de INSTALACION o MONTAJE.
Se requiere INSPECCION.
LIMPIESE la pieza o el montaje.
Ejecutese una MEDICION mecánica o del tiempo.
LUBRIQUESE la pieza o el montaje.
Indica que se daráuna LLAVE DE TUERCAS o el TAMAÑO DE HERRAMIENTA.
APRIETESE hasta un par torsor especifico.
Ceri—rese de que están alineadas las marcas de balance en el rotor.
EJECUTESE una MEDICION elŽctrica.
Para informaci—n adicional refiŽrase a otro emplazamiento de este manual o a otra publicaci—nanterior.
Favor de siempre llevar ropa protectora.
Indica que los componentes pueden ser pesados.
Acceso a Sitio Web para localizar su agente Holset m‡s cercano.
Ir a la tabla de materias
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Symboles - Fran• aisLes symboles suivants sont utilisŽs dans ce manuel pour aider ˆ communiquer le but des instructions. QuandlÕun de ces symboles apparait, il Žvoque le sens dŽfini ci-dessous:
Indique une opŽration de DEPOSE.
Indique une opŽration de MONTAGE.
LÕINSPECTION est nŽcessaire.
NETTOYER la pi ce ou lÕensemble.
EFFECTUER une MESURE mŽcanique ou de temps.
GRAISSER la pi ce ou lÕensemble.
Indique quÕune DIMENSION DE CLE ou DÕOUTIL sera donnŽe.
SERRER ˆ un couple spŽcifique.
SÕassurer que les rep res dÕŽquilibrage sur lÕensemble de rotor sont alignŽs.
EFFECTUER une MEASURE Žlectrique.
Se reporter ˆ un autre endroit dans ce manuel ou ̂ une autre publication pour obtenir desinformation plus compl tes.
Il faut toujours mettre v tements de protection.
Indique que les composants peuvent tre lourds.
Acc s au site Web pour trouver lÕagent Holset le plus proche.
Aller au sommaire
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Introduction
S’mbolos - Portugu sOs s’mbolos a seguir ser‹ o utilizados neste manual para facilitar a comunica•‹ o das instru•› es e seuesignificados est‹ o dŽscritos abaixo.
Indica um passe de DESMONTAGEM.
Indica um passo de MONTAGEM.
Requer inspe•‹ o.
LIMPE a pe•a ou conjunto.
Requer Medi•‹ o mec‹ nica ou de tempo.
LUBRIFIQUE a pe•a ou o conjunto.
Indica necessidade de APERTO.
TORQUEAR de acordo com o especificado.
Assegure-se de que as MARCAS DE BALANCEAMENTO do conjunto eixorotor estejam alinhadas.
Requer medi•‹ o ELƒTRICA.
Procure em outra se•‹ o deste manual ou em publica•‹ o par obter informa•› es adicionais
Por favor, sempre utilize EPI (Equipamento de Protecao Individual)
Indica que os componentes podem estar pesados.
Visite o Website para encontrar o seu Agente Holset mais perto.
V‡ para Conteœdo
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2:1
Turbocharger IdentificationDataplate
Center Housing Rotating Assembly (CHRA) (2)
NOTICEDataplates will be fitted to compressor housing (8).
Information from dataplate must be quoted for service andparts support.
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Component Identification
Installation OptionsType A
Type B
Type C
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Installation OptionsType D
Type E
Type F
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Component Identification
Exploded View
74
10660
73
76
75
75
77
96
81
28
43
113
114
4
135
135
761
66
33
38
60
12
1164
11
91
53
41
36
6
13
31
1632
62
5
8
Actuator Mounting
Bracket Variant
NOTICEExploded views represent a generic build standard. Parts may be added or subtracted in specific
applications.
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2:5
Exploded View - Optional Parts
4
80
67
5
74 74
76
74
136
81
Component Identification
NOTICEExploded views represent a generic build standard. Parts may be added or subtracted in specific
applications.
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2:6
Component Identification
Component ListItem No. Description Quantity
All Applications
1 Repair Kit CHRA (Core)* 1
2 CHRA (Core) 1
4 Bearing Housing 15 Turbine Housing 1
6 Assembly, Turbine Wheel 1
7 Compressor Wheel 1
8 Compressor Housing 1
11 Journal Bearing* 2
12 Thrust Bearing* 1
13 Split Ring Seal, Turbine* 1
16 Split Ring Seal, Compressor* 1
28 V-Band Clamp, Turbine 1
31 Oil Slinger 1
32 O-Ring Seal, Bearing Housing* 1
33 Oil Baffle 1
36 Thrust Collar 1
38 Heat Sheild 1
41 O-Ring Seal, Compressor Housing* 1
43 Oil Seal Plate 1
53 Gasket, Oil Outlet 1
60 Plain Washer 1
61 Locknut, Compressor Wheel 1
62 Locknut, V-Band 1
64 Retaining Ring, Bearing* 2
66 Retaining Ring, Insert 1
67 Bolt, Exhaust Adaptor 1
80 Exhaust Adaptor 1
91 Retaining Ring, Compressor Housing 1
96 Screw, V-band 1
113 Adaptor, Oil Inlet 1
114 O-Ring Seal, Oil Inlet 1
135 Dowel, pin 2
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Component Identification
Component ListItem No. Description Quantity
Wastegate Applications
136 Bracket Kit 1
74 Wastegate Kit comprising: 1
73 Actuator 175 Hose Clip 2
76 End Link, Assembly 1
77 Retaining Ring, End Link 1
106 Screw, Actuator 2
60 Plain Washer 2
128 Jam Nut 0/1
81 Hose 1
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Component Identification
Purchasable Service Tools
The following special tools can be purchased from your local Authorised Repair Location. The use of thesetools is recommended and where necessary they are shown in the appropriate service procedure.
Service Tools
Part No. Tool Description Tool Illustration
3575186 Circlip Pliers
CAUTION
All Service and Maintenance settings are shown in Cummins Turbo Technologies'. It is essential that
these settings are used. Common tools found in mechanic’s tool box not included.
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Troubleshooting and Diagnosis
Fault Finding chart - All Applications
E n g i n e L a c k s P o w e r
B l a c k E x h a u s t S m o k e
B l u e E x h a u s t S m o k e
H i g h O i l C o n s u m p t i o n
T u r b o c h a r g e r N o i s y
E n g i n e R u n n i n g H o t
P o o r T r a n s i e n t R e s p o n s e
S m o k e
C y c l i c S o u n d f r o m t
h e T u r
b o c h a r g e r
O i l L e a k f r o m C o m p r e s s o r
S e a l
O i l L e a k f r o m T u r b i n e S e a l
Dirty air cleanerClean or replace element according to manufacturer’s recommendations
Restricted compressor intake ductRemove restriction or replace damaged parts as required
Restricted air duct from compressor to intake manifoldRemove restriction or replace damaged parts as required
Restricted intake manifoldRefer to engine manufacturer’s manual and remove restriction
Air leak in feed from air cleaner to compressorReplace seals, gaskets or tighten fasteners as required
Air leak in feed from compressor to intake manifoldReplace seals, gaskets or tighten fasteners as required
Air leak between intake manifold and engineRefer to engine manufacturer’s manual and replace gaskets or tighten fasteners as required
Foreign object in exhaust manifold (from engine)Refer to engine manufacturer’s manual and remove obstruction
Restricted exhaust systemRemove restriction or replace damaged parts as required
Exhaust manifold cracked, gaskets blown or missingRefer to engine manufacturer’s manual and replace gaskets or damaged parts as required
Gas leak at turbine inlet/exhaust manifold jointReplace gasket or tighten fasteners as required
Gas leak in ducting after turbine outletRefer to engine manufacturer’s manual and repair leak
Restricted turbocharger oil drain lineRemove restriction or replace damaged parts as required
Restricted engine crankcase breatherRefer to engine manufacturer’s manual, clear restriction
Turbocharger bearing housing sludged or cokedChange engine oil and oil filter, overhaul or replace turbocharger as required
Fuel injection pump or fuel injectors incorrectly setRefer to engine manufacturer’s manual and replace or adjust faulty components as required
Engine valve timing incorrectRefer to engine manufacturer’s manual for correct settings and adjust as required
Worn engine piston rings or linersRefer to engine manufacturer’s manual and repair as required
Burnt valves and/or pistonsRefer to engine manufacturer’s manual and repair as required
Excessive dirt build up on compressor wheel and/or diffuser vanesContact your local approved dealer
Turbocharger damagedFind and correct cause of failure, or replace turbocharger as necessary
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Troubleshooting and Diagnosis
Fault Finding chart - Wastegate Applications
E n g i n e L a c k s P o w e r
B l a c k E x h a u s t S m o k e
B l u e E x h a u s t S m o k e
H i g h O i l C o n s u m p t i o n
T u r b o c h a r g e r N o i s y
E n g i n e R u n n i n g H o t
P o o r T r a n s i e n t R e s p o n s e
S m o k e
C y c l i c S o u n d f r o m t
h e T u r b o c h a r g e r
O i l L e a k f r o m C o m p r e s s o r S e a l
O i l L e a k f r o m T u r b i n e S e a l
Failed actuator diaphragmReplace using correct Actuator Service Kit
Seized wastegate valve (in turbine housing)Free valve in accordance with details in the appropriate Holset publication replace completeturbine housing sub-assembly
Leaking actuator hoseReplace hose and clips
Wastegate mechanism set incorrectlyContact your approved Holset agent for correct setting procedure
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Dial Gauge and Dial Gauge Adaptor
Pressure Gauge Regulated Air SupplyMax 300 kPa (45 lbf/in2)
Component Testing and Replacement
Service ToolsThe following special tools are recommended to perform procedures in this manual. The use of these tools isshown in the appropriate procedure.
Part No. Tool Description Tool Illustration
Torque Wrench
(Refer to Service Data Sheet for required torque ranges)
CAUTION
All Service and Maintenance settings are shown in Cummins Turbo Technologies' Service Data Sheet.It is essential that these settings are used. Common tools found in mechanic’s tool box not included.
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WARNING
Always wear safety glasses.
WARNING
Always protect face and hands from hot fluidsand hot surfaces.
WARNING
Always ensure turbocharger rotor is stationarybefore taking service action.
CAUTION
Air, oil and coolant hoses/pipes perform criticalfunctions at pressure and temperature. To avoid
leakage and potential turbocharger and enginefailures, always use components specified by
engine manufacturer.
Oil LeakageInlet Adapter, Bearing HousingBearing Housing M10 x 1.25
Pipe Fitting 11/16-16 UN (19 mm)
WARNING
Always ensure turbocharger rotor is stationarybefore taking service action.
Replacement seals and adapters should be fittedwithout sealant as this can contaminate oil. Torquetighten adapter to value shown inService Data Sheet .
It is important to avoid kinked pipes during servicingand subsequent operation.
Outlet Flange, Bearing HousingM6 x 1.0
WARNING
Oil may be hot. Never take service action with
engine running.
Replacement gaskets and flange fasteners should befitted without sealant as this can contaminate oil. Torquetighten fasteners to value specified by enginemanufacturer.
All outlet pipes should be free flowing without kinks andsharp bends and decline at overall angle not less than30 degrees below horizontal.
Component Testing and Replacement
On Engine Checks
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Component Testing and Replacement
WARNING
Always wear safety glasses.
Closed crankcase ventilation systems may deposit oil incompressor housing. Where practical remove intake
system pipework every 50,000 km (30,000 miles) tocheck housing, compressor wheel and inlet bafflecondition.
CAUTION
Always clean housing before final inspection andreassembly.
Refer to Turbine and Compressor Housings fordisassembly, check and reassembly instructions.
Refer to Cleaning of Housings to clean housing. Rotorcomponents can be cleaned using non metallic bristlebrush.
Coolant LeakageEnsure coolant pipe installations produce upward waterflow. Coolant circuits generally flow from enginecrankcase water-jacket to thermostat housing.Turbocharger circuit should use a low inlet port andhigh outlet port with pipe system rising progressivelyavoiding high pockets. Always replace pipe clips where
fitted.
WARNING
Always protect face and hands from hot fluidsand hot surfaces.
Connections, Bearing Housing
M8 x 1.25
WARNING
Air, oil and coolant hoses perform critical
functions at pressure and temperature. To avoidleakage and potential turbocharger and enginefailures, always use components specified by
engine manufacturer.
Repair by replacement of coolant inlet and outletfittings. Torque tighten adapters to value specified byengine manufacturer.
CAUTION
Do not use sealant as this may affect performanceof o-ring seals.
Where housing threads are damaged removeturbocharger for Service and Overhaul.
Carbon build up and high
temperature laquering
Oil aerosol hitting wall
and forming carbon
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WARNING
Always wear safety glasses.
Gas LeakageTurbine housing flange leakage will cause soot
formation on flange. Check exhaust manifold to flangeseal. Ensure fasteners are torque tightened to valuespecified by engine manufacturer.
Check flange for cracks and ensure flatness is within0.1 mm (0.004 in).
Check turbine housing gasket for signs of damagewhich would cause leakage. Always replace damagedgaskets.
M8 x 1.25 (13 mm A/F)
Where used, check exhaust adapter flange sealing facefor cracking and distortion.
If exhaust seal is compromised replace gasket/exhaustadapter. Torque bolts to value specified by enginemanufacturer.
Where turbine housing flange sealing face or exhaustconnection is cracked, remove turbocharger and referto Turbine and Compressor Housings for removal,checks and refitting.
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WARNING
Always wear safety glasses.
Air Leakage
WARNINGNever attempt to check actuator using air supplied
from running engine.
Check for wastegate actuator rod movement and airleakage on engine. Follow checking proceduredescribed in Wastegate Actuator Checks .
Component Testing and Replacement
Visual ChecksCheck for cracked, bent or damaged compressor wheelblades.
CAUTION
Never attempt to straighten compressor or turbineblades.
Where practical, check for cracked, bent or damagedturbine wheel blades.
With intake system disconnected from compressorhousing, it may be possible to check visually for excessbearing axial and radial clearances.
If light finger pressure causes contact betweencompressor or turbine wheel and respective housingremove turbocharger from engine for Service andOverhaul.
If bearing condition is in doubt, always check BearingClearance.
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Secure turbine housing and check axial clearance usingdial gauge.
Ensure clearance is within MIN/MAX values shown onService Data Sheet .
Component Testing and Replacement
Bearing Clearance
Check radial movement at compressor impeller noseusing dial gauge.
Ensure movement is within MIN/MAX TIR (TotalIndicator Reading) values shown on Service DataSheet .
If either axial clearance or radial movement does notmeet specification refer to turbocharger Service andOverhaul.
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NOTICEWhere it is necessary to remove actuator before
commencing planned actions on turbine orcompressor housing, refer to Actuator Removal
for more details.
CAUTION
On turbochargers with compressor mounted
wastegate actuators remove actuator at this stage.
Component Testing and Replacement
Turbine and Compressor Housings
WARNING
Always wear safety glasses.
WARNING
If there is any possibility that o-ring seal has beensubject to fire, always wear neoprene gloves when
handling.
Compressor HousingPlace compressor inlet on clean flat surface.
Mark compressor housing, bearing housing andretaining ring to record correct orientation. This actionassists in re-assembling pinned components anddefines orientation of retaining ring.
Remove retaining ring, compressor housing usingsuitable circlip pliers.
Secure turbine housing flange in vice or ensureturbocharger is stable on clean flat surface.
Use soft metal hammer on two opposing areas ofcompressor housing at 180 degrees. When housingcomes loose, safely lift it out of bearing housingengagement.
CAUTION
Take care. Do not damage compressor blades as
compressor housing is removed.
CAUTION
Compressor housing is pinned to bearing
housing. Take care. Do not bend locating pin.
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Remove o-ring seal, compressor housing (41) anddiscard.
Component Testing and Replacement
Inspect internal profile of compressor housing forscoring damage due to possible contact with
compressor wheel. Check retaining ring groove is freefrom deposits and is not worn.
Move to Cleaning of Housings if deposits are visible.
Refer to Housing Reassembly to fit new or existinghousing.
CAUTION
Good groove and abutment face condition arecritical to integrity of compressor housing to
bearing housing joint.
Indelible ink marks may be removed by cleaningprocess. Before cleaning always ensure alignmentmarks are scribed with metal chisel or scribe.
Refer to Cleaning of Housings for recommended
cleaning processes.
CAUTION
Always clean housing before final inspection andreassembly.
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4:9
Component Testing and Replacement
Place turbine outlet on clean flat surface or, where thisis impractical, secure turbine housing flange in vice.
Mark turbine housing, bearing housing and v-bandclamp, turbine. This action assists in reassemblyprocess defining correct component orientation.
WARNING
Always wear safety glasses.
Turbine Housing
NOTICEIt is possible to remove turbine housing without
disturbing turbine mounted wastegate actuators.
CAUTION
On turbochargers with compressor mounted
wastegate system actuator must be removed atthis stage.
Refer to Actuator Removal for more details.
M6 x 1 (10 mm)
Loosen locknut, v-band and remove v-band, turbine.
CAUTION
Locknuts must be replaced every time they areremoved to ensure long term clamp loading ofv-band.
Remove CHRA (core) assembly from turbine housing.
To free joint, use soft hammer on two opposing areas ofturbine housing at 180 degrees . When loose, safely liftassembly out of turbine housing engagement.
CAUTION
Never direct hammer blows on to turbine housing
flange
CAUTION
Take care. Do not damage turbine blades as core
assembly (CHRA) is removed.
CAUTION
Compressor housing is pinned to bearinghousing. Take care. Do not bend locating pin.
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Component Testing and Replacement
CAUTION
Turbine housings can exhibit cracking when
subject to excessive thermal and mechanical
loads.Cracking of turbine housing inlet flange and inlet ductgenerally requires turbine housing replacement.Acceptance and rejection guidelines are shown in thisillustration. If exhaust gasket is available, alwaysensure that any cracks lie within its sealing area
Check turbine housing inlet flange flatness is within0.1 mm (0.004 in) before retaining component forre-use.
Check fastener hole diameter is not more than 1.5 mmlarger than max. thread diameter of fastener.
CAUTIONWhere crack will cause leakage to atmosphere
turbine housing must be replaced.
Cracking of internal wall at entry to turbine wheel(tongue) is acceptable service condition and turbinehousing may be re-used.
M8 x 1..25 - 6H
Where fitted, remove exhaust adapter to check gasketcondition.
Check outlet flange sealing face for cracking anddistortion. If exhaust seal is compromised replacegasket/adapter. Where turbine housing flange iscracked, replace turbine housing.
When refitting exhaust adapter and gasket, torque boltsto the value specified by engine manufacturer.
Indelible ink marks may be removed by cleaningprocess. Before cleaning always ensure alignmentmarks are scribed with metal chisel or scribe.
Refer to Cleaning of Housings for recommendedcleaning processes. Pay particular attention to surfacesclose to turbine wheel and bearing housing location.
CAUTION
Always clean housing before final inspection andrefitting.
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WARNING
Always wear safety glasses.
Visually inspect parts to detect signs of burning andother conditions in order to obtain as much informationas possible before washing.
CAUTION
Housing surfaces adjacent to turbine and
compressor wheels must be clean, smooth andfree from deposits.
Component Testing and Replacement
Cleaning of Housings
Soak housings in non-corrosive low flash point metalcleaner to loosen deposits.
Dry components using compressed air.
Scale like deposits, if any, must be removed by usingnon metallic bristle brush. After removing deposits,re-wash and dry components.
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Component Testing and Replacement
WARNING
Always wear safety glasses.
It is permissible to bead blast turbine housing ifchemical and brush cleaning is not effective.
WARNINGDo not bead blast Aluminium and Cast Ironcomponents together.
CAUTION
Prevent bead spray impinging directly on turbine
flange threads by masking or plugging.
CAUTION
Prevent bead spray impinging directly on
wastegate valve spindle as beads can penetrate
spindle bore, leading to spindle seizure.After removing deposits, re-wash and dry components.
Refer to Reassembly of Housings for re-assemblyinstructions
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WARNING
Always wear safety glasses.
Turbine HousingApply high temperature anti-seize compound to bearinghousing locating bore of turbine housing.
Position v-band over turbine housing.
Align marks applied to turbine housing, bearing housingand v-band clamp to establish component orientation.This action assists in re-assembling pinnedcomponents.
Component Testing and Replacement
Reassembly of Housings
Slide CHRA (core) and compressor housing assemblyinto turbine housing. Use alignment marks to locateassembly correctly on locating pin fitted to turbinehousing.
M6 x 1.0 (10 mm)
CAUTIONEnsure v-band screw and new locknut are cleanand oil free before torque tightening.
Locate v-band to orientation marks. Apply molycoteanti-seize compound to v band fastener threads. Insertscrew and apply locknut. Torque tighten to valuespecified in Service Data Sheet .
Using soft faced hammer, tap v-band clamp three orfour times at equally spaced distances around itscircumference.
Re-tighten to specified torque.
Check for free rotation of rotor assembly.
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WARNING
Always wear safety glasses.
Compressor HousingLubricate new o-ring seal (41) with clean engine oil andinsert into bearing housing groove.
CAUTION
Always fit new seal.
CAUTION
Take care. Do not damage compressor blades.
Component Testing and Replacement
CAUTION
Take care. Do not bend locating pin.
Position retaining ring, compressor housing over coreand turbine housing assembly with chamfered facetowards turbine housing. Correctly align compressorhousing using disassembly orientation marks to ensurelocation pin aligns with mating hole in bearing housing.Press compressor housing into position taking care notto trap o-ring.
NOTICEWhere turbine housing is not already fitted to
CHRA (core), compressor housing should beplaced on its inlet face. CHRA can then beinserted using technique already described.
Turn turbocharger on to compressor inlet face. Refitretaining ring, compressor housing using suitable circlippliers.
CAUTION
Retaining ring must be fitted with chamfered faceupwards away from compressor housing.
Tap ends of retaining ring lightly with hammer and driftto ensure that it is properly located into its groove inbearing housing.
CAUTION
Ensure drift does not damage bearing housing.
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Check for free rotation of rotor assembly.
CAUTION
To refit wastegate actuator refer to Actuator
Reassembly.
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WARNING
Always wear safety glasses.
WARNING
Always protect face and hands from hot fluidsand hot surfaces.
WARNING
Always ensure turbocharger rotor is stationary
before taking service action.
NOTICEDo not remove turbocharger from engine unlesson-engine actuator check is impractical'
Place turbocharger on suitable workbench. Use small
flat screwdriver to remove hose clip and disconnecthose from actuator air inlet fitting.
Discard hose clips (75).
Component Testing and Replacement
Wastegate Actuator Checks
Connect clean regulated compressed air supply toactuator air inlet fitting and secure hose.
WARNING
Ensure hose is securely fastened to air inlet fitting
using appropriate hose clip and clamp load. Highpressure air jet from loose hose can cause facial
injury.
WARNING
Avoid touching actuator rod when air pressure is
applied. Finger injury may result from suddenmovement of assembly.
Apply pressure to actuator from regulated compressedair supply Max 300 kPa (45 lbf/in2) and check foractuator movement.
If air leak is found, actuator is damaged and must bereplaced. Refer to Actuator Removal and ActuatorReassembly
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WARNING
Always wear safety glasses.
CAUTION
Do not remove turbocharger from engine unlessactuator check is impractical due to space or
access limitations or where on-engine check hasshown problem exists.
Place turbocharger on suitable workbench. Use smallflat screwdriver to remove hose clip and disconnecthose from actuator air inlet fitting.
Discard hose clips (75).
Component Testing and Replacement
If air leak is not found and shaft does not move,disconnect actuator end link from crank journal inaccordance with Actuator Removal.
If shaft does not move with air pressure applied,actuator is damaged and must be replaced. Refer toActuator Removal and Actuator Reassembly.
If disconnected shaft moves with air pressure applied,actuator is not damaged. Check valve mechanism forseizure according to procedure in WastegateMechanism Check.
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WARNING
Always wear safety glasses.
Place turbocharger on suitable workbench. Use pointnose pliers to remove actuator clip.
Component Testing and Replacement
Actuator Removal
WARNING
Take care. Finger injury may result from sudden
movement of assembly.
Apply small amount of air pressure to actuator until endlink moves to release actuator preload.
Carefully slide end link off crank journal. If end link doesnot move, use screw driver to prise end link off crank
journal.
Remove air supply and discard hose clips (75).
CAUTION
Do not rotate actuator rod relative to actuator asthis can damage actuator internal components.
CAUTION
Before removing actuator, record orientation of airinlet fitting.
CAUTION
Do not adjust actuator end link. This setting iscritical to actuator performance.
Compressor Mounted Actuator
M8 (12 mm)
Remove actuator fasteners and remove wastegateactuator.
Turbine Mounted ActuatorM8 (12 mm)
Remove actuator fasteners and remove wastegateactuator.
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WARNING
Always wear safety glasses.
Rotate crank lever on cross shaft by hand.
If lever moves smoothly with small resistance, refer toWastegate Actuator Checks to re-check for movementof disassembled actuator.
If lever is seized or moves loosely, turbine housing mayrequire replacement. However, it may be possible tofree seized crank lever.
Component Testing and Replacement
Wastegate Mechanism Check
Some ash, if coming from a leaking EGR cooler, iswater soluble. Soaking in water may release valve.
Soak wastegate valve and lever mechanism inpenetrating oil.
Some turbine housing options do not have open accessto wastegate valve but, with care, soaking with
penetrating oil may still be possible.
CAUTION
Take extra care when attempting to free wastegatevalve mechanism. Any damage will result in needto replace turbine housing.
Clamp pair of mole (vice) grips to crank lever andgently apply pressure to rotate lever.
If this process does not free valve mechanism, refer toTurbine and Compressor Housing to fit new turbinehousing.
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WARNING
Always wear safety glasses.
Radial cracks can occur around valve seat whenturbocharger has been abused or overheated.
CAUTION
If wastegate valve mechanism shows any fault, itmust be replaced. Using damaged turbine
housings will lead to inferior performance ofturbocharger, and risk of irreparable damage to
both turbocharger and engine.
Component Testing and Replacement
Crank journal can be worn by partial seizure ofwastgate valve mechanism. Scoring may be caused byarduous local environmental conditions. Journalclearance with end link must not exceed 0.50 mm
(0.020 in).If wastegate mechanism shows excessive wear, refer toTurbine and Compressor Housings to fit new turbinehousing.
Same failure conditions can lead to elongation of endlink bore which locates on crank journal. End link
clearance with crank journal must not exceed 0.50 mm(0.020 in).
If end link shows excessive wear, refer to ActuatorReassembly to fit new actuator.
CAUTION
If actuator shows any fault, it must be replaced.
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WARNING
Always wear safety glasses.
Compressor Mounted Actuator -Half Turn End Link
CAUTION
Contact your local approved agent for correctreplacement actuator kit (74). It is important to
quote correct turbocharger assembly number toensure supply of correct pre-set actuator.
Before refitting existing actuator ensure end link and jam nut are locked in original position.
NOTICESome actuator kits are supplied with end link
locked to jam nut. Loosen end link from jam nut
before fitting actuator.
Thread new end link several turns on to shaft of newpre-set actuator assembly.
Component Testing and Replacement
Wastegate Actuator Reassembly
Adjusting nut
Gimbal
Rotate crank lever to close wastegate valve (pushedtowards compressor end). Position actuator assemblyin correct orientation next to turbocharger. Fit end linkover crank pin.
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4:22
Component Testing and Replacement
WARNING
Always wear safety glasses.
Attempt to slide actuator bracket over its retaining lugs.If actuator bracket fouls on lugs or there is significantclearance between bracket and lugs, actuator rodlength requires adjustment.
To adjust length of actuator assembly, remove fromturbocharger. Rotate end link to shorten or lengthen rodas appropriate. Re-fit, until underside of actuatorbracket will just fit over mounting lugs with less than 0.5mm (0.020 in) gap.
CAUTION
Do not apply force to push actuator on tomounting lugs.
Rod length setting is correct if, by rotating end linkclockwise by half turn, actuator bracket fouls on lugs.
M8 (12 mm)
Fit actuator mounting fasteners with washers andtorque tighten to value shown inService Data Sheet .
Fit new spring clip to retain end link on crank pin.
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4:23
Component Testing and Replacement
WARNING
Always wear safety glasses.
Connect clean air supply to actuator air inlet fittingregulated to MAXIMUM of 3 bar (44 lbf/in2). Apply airpressure progressively to remove pre-load from jam
nut.
Spacer piece (TAST - Turbocharger ActuatorSetting Tool)
(10 mm A/F)
Loosen spacer piece by turning jam-nut anti-clockwise(counter-clockwise). Remove and discard tie wrap andspacer piece.
Turn jam nut counterclockwise and hand tighten againstend link.
Disconnect air supply.
Spacer Clamp (TAST - TurbochargerActuator Setting Tool)3mm Allen Key
(10 mm A/F)
Loosen and remove spacer clamp (TAST -Turbocharger Actuator Setting Tool) using 3 mm Allenkey. Turn jam nut counterclockwise and hand tightenagainst end link.
Disconnect air supply.
CAUTION
Reacting fastening torque through crank journal
may damage actuation mechanism.
Torque tighten jam nut to value shown in Service Data
Sheet . Use adjustable spanner clamped on end linkflange to provide torque reaction.
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4:24
WARNING
Always wear safety glasses.
Refit air supply hose with new clips (75). Clips shouldbe crimped closed using pinsers. Crimp gap will varydue to spring back and hose type but will not be lessthan 0.6 mm (0.025 in).
Suitable alternative hose clamps can be used.
CAUTION
Before mounting turbocharger on engine, checkfor full and free wastegate movement.
CAUTION
Ensure that air feed pipe is free from kinks and
has no chafe marks.
Component Testing and Replacement
Infinitely Adjustable End LinkEnsure new end link is threaded on to actuator shaft.
NOTICESome actuator kits are supplied with end linkadjusting nut locked against jam nut. Useadjustable spanner clamped on end link flange
when loosening.
M8 (12 mm A/F)
Fit actuator mounting fasteners with washers andtorque tighten to value specified in Service Data Sheet .
CAUTION
Actuator clamp must remain securely fastened in
position at this stage.
If end link gimbal and crank journal will not align, rotateknurled adjusting nut until gimbal can be fitted to crank
journal without using force.
CAUTION
Do not force end link on to crank journal.
Adjusting nut
Gimbal
A B
Adjusting nut
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4:25
Component Testing and Replacement
Torque tighten jam nut to value specified in ServiceData Sheet . Use adjustable spanner clamped on endlink flange to provide torque reaction.
CAUTION
Reacting fastening torque through crank journal
may damage actuation mechanism.
CAUTION
Ensure adjusting nut does not rotate during jam
nut loosening and rotation.
(10 mm A/F)
Rotate knurled adjusting nut by 1 to 2 turns to increaselength of actuator rod and ensure wastegate valve isnot in closed position.
Now, counter-rotate adjusting nut to shorten effectivelength of actuator assembly. As wastegate valveremakes contact with its seat, resistance to rotation ofnut will increase. Hand tighten nut to seat wastegatevalve which achieves correct actuator rod length.
Connect clean air supply to actuator air inlet fittingregulated to MAXIMUM of 3 bar (44 lbf/in2). Apply airpressure progressively to remove pre-load from jamnut.
Turn jam nut counterclockwise by hand. Remove anddiscard tie wrap and spacer piece. Continue turning jamnut in same direction, and hand tighten against end link.
Disconnect air supply.
WARNING
Always wear safety glasses.
Fit new splt pin, end link.
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4:26
Component Testing and Replacement
Turbine Mounted Actuator -Infinitely Adjustable End Link
CAUTION
Contact your local approved agent for correct
replacement actuator kit. It is important to quotecorrect turbocharger assembly number, serial
number and type from dataplate to ensure supplyof correct pre-set actuator.
NOTICESome actuator kits are supplied with end linklocked to jam nut. Loosen end link from jam nut
before fitting actuator.
Before refitting existing actuator ensure end link and jam nut are locked in original position.
Threaded new end link on to actuator shaft.
WARNING
Always wear safety glasses.
Refit air supply hose with new clips. Clips should becrimped closed using pincers. Crimp gap will vary dueto spring back and hose type but will not be less than0.6 mm (0.025 in).
Suitable alternative hose clamps can be used.
Adjusting nut
Gimbal
3mm Allen Key
Loosen and remove actuator clamp.
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4:27
Component Testing and Replacement
Fit new splt pin, end link.
(10 mm A/F)
Rotate knurled adjusting nut by 1 to 2 turns to increase
length of actuator rod and ensure wastegate valve isnot in closed position.
Now, counter-rotate adjusting nut to shorten effectivelength of actuator assembly. As wastegate valveremakes contact with its seat, resistance to rotation ofnut will increase. Hand tighten nut to seat wastegatevalve which achieves correct actuator rod length.
Turn jam nut counterclockwise and hand tighten againstend link.
If end link gimbal and crank journal will not align, rotateknurled adjusting nut until gimbal can be fitted to crank
journal without using force.
CAUTION
Do not force end link on to crank journal.
A B
Adjusting nut
WARNING
Always wear safety glasses.
M8 (12 mm A/F)
Ensure spine of spacer piece is upright (i.e. facing awayfrom mounting bracket). Fit actuator mounting studs intobracket mounting holes
Fit actuator mounting nuts and torque tighten to valueshown in Service Data Sheet .
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4:28
Component Testing and Replacement
Refit air supply hose with new clips. Clips should becrimped closed using pincers. Crimp gap will vary dueto spring back and hose type but will not be less than0.6 mm (0.025 in).
Suitable alternative hose clamps can be used.
WARNING
Always wear safety glasses.
CAUTION
Ensure adjusting nut does not rotate during jamnut loosening and rotation.
Connect clean air supply to actuator air inlet fittingregulated to MAXIMUM of 3 bar (44 lbf/in2). Apply airpressure progressively to remove pre-load from jamnut.
Turn jam nut counterclockwise by hand. Remove anddiscard tie wrap and spacer piece. Continue turning jamnut in same direction, and hand tighten against end link.
Disconnect air supply.
Torque tighten jam nut to value shown in Service DataSheet . Use adjustable spanner clamped on end link
flange to provide torque reaction.
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4:29
Component Testing and Replacement
Replace bracket by inserting setscrews through plainwashers into bracket and correctly positioned spacers.
Locate setscrews into threaded holes in turbinehousing.
Torque tighten setscrews and cap head screw to valuespecified in Service Data Sheet .
Actuator Bracket Removal and Reassembly
WARNING
Always wear safety glasses.
M8 x 1.25 (13 mm A/F)
Remove setscrews, plain washers and retain withmounting spacers and bracket.
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5:1
Turbocharger Service and Overhaul
Service ToolsThe following special tools are recommended to perform procedures in this manual. The use of these tools isshown in the appropriate procedure. These tools can be purchased from your local Authorised Repair Location.
Part No. Tool Description Tool Illustration
Torque Wrench
Dial Gauge and Dial Gauge Adaptor
Pressure Gauge Regulated Air SupplyMax 300 kPa (45 lbf/in2)
CAUTION
All Service and Maintenance settings are shown in Cummins Turbo Technologies' Service Data Sheet.It is essential that these settings are used. Common tools found in mechanic’s tool box not included.
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5:2
WARNING
Always wear safety glasses.
WARNING
If there is any possibility that an o-ring seal has
been subject to fire, always wear neoprene gloveswhen handling.
NOTICEBefore disassembly, check for turbine andcompressor blade damage. Measure bearing
radial movement and axial clearance to ensureCHRA (core) is within MIN/MAX values shown onService Data Sheet .
Turbocharger Service and Overhaul
Disassembly
CAUTIONThis turbocharger requires new standard of
balancing process on rebuild using proprietaryvibration sorting rig (VSR). Do not commencedisassembly if VSR balancing facility is not
available to balance rebuilt core If in any doubtplease contact local Holset agent.
Locate CHRA (2) on to 12 mm 12 point socket locatedin suitable fixture.
M5 x 0.8 L.H. (8mm)
Remove locknut, compressor wheel (62).NOTICE
Left hand thread.
Remove compressor wheel (7).
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5:3
WARNING
Always wear safety glasses.
Remove remaining CHRA from fixture taking care tohold assembly, turbine wheel in place. Gently slide
bearing housing (4) off assembly, turbine wheel (6).It is permissible to tap protruding turbine shaft gentlywith soft hammer if split ring seal is stuck in its bore.
Turbine end journal bearing and heat shielddisassemble from core at this stage.
Turbocharger Service and Overhaul
Remove journal bearing (11) and heat shield (38).
Carefully remove split ring seal, turbine (13) * and
discard.CAUTION
Take care. Do not score turbine wheel and shaftassembly.
With bearing housing (4) on flat clean surface, usesuitable circlip pliers to remove insert, retaining ring(66).
It is practical to use free hand to contain disassembledring whilst releasing pliers.
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5:4
WARNING
Always wear safety glasses.
WARNING
Do not use excess force when prising under oilseal lip. Fragments may break out at high velocity.
Remove oil seal plate (43) using two screw driversunder exposed lip to prise out seal plate.
Turbocharger Service and Overhaul
Remove oil slinger (31) and baffle sub-assembly fromoil seal plate.
Using precision screwdriver, remove split ring seal,compressor (16)
* to disassemble oil slinger (31) from
oil baffle (33) *.
WARNING
If there is any possibility that an o-ring seal hasbeen subject to fire, always wear neoprene gloves
when handling.
Remove and discard o-ring seal, bearing housing (32) * and o-ring seal, compressor housing (41) *.
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5:5
WARNING
Always wear safety glasses.
NOTICE
If stuck in position use screwdriver inserted atturbine end to dislodge.
Turn bearing housing over so that thrust bearing (12) *,thrust collar (36) and compressor end journal bearing(11) * drop out of assembly under own weight.
Turbocharger Service and Overhaul
Inboard bearing retaining rings are intended to remainin housing. Where removal is essential bearing boredamage can be avoided by locating precisionscrewdriver under angled end of ring to lift it out of
groove. Then use rotary motion until 11 / 2 coils of ringcome clear of groove.
When removal is essential, it is acceptable to replaceproprietary rings with equivalent circlips.
Replacement of original type of spring ring can beaccomplished by pre-compressing rings into thin walled
tube with external diameter equal to minumum bearingbore size. Place tube through bearing bore with endface adjacent to ring groove. Push spring ring out ofend of tube to allow it to expand into its location.
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5:6
WARNING
Always wear safety glasses.
Visually inspect all parts to detect signs of burning andother fault conditions in order to obtain as much
information as possible before washing.
CAUTION
Housing surfaces adjacent to turbine andcompressor wheels must be clean, smooth and
free from deposits.
Turbocharger Service and Overhaul
Component Cleaning
Soak components in non-corrosive low flash point metalcleaner to loosen deposits.
Dry components using compressed air.
Protect sliding surfaces of cleaned parts againstcorrosion by applying clean engine oil.
Scale like deposits, if any, must be removed by usingnon metallic bristle brush. After loosening deposits withbrush, wash and dry components as above.
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5:7
WARNING
Always wear safety glasses.
WARNING
Do not bead blast aluminium and cast iron
components together.
It is permissible to bead blast turbine housing ifchemical and brush cleaning is not effective.
Exhaust adapter threads can be cleaned usingspecified thread taps.
CAUTION
Prevent bead spray impinging directly on coverplate threads by masking or plugging.
Always protect threads during bead blasting and
clean with specified thread tap after blasting.
Prevent bead spray impinging directly on
wastegate valve spindle as beads can penetratespindle bore, leading to seizure.
Turbocharger Service and Overhaul
Oil fittings M10 X 1.25 ; M6 x 1.0
Coolant fittings M8 x1.25
It is important that oil chamber of bearing housing isfree of carbon before re-building. If heavy depositspersist after repeat washing replace bearing housing (4).
CAUTION
Do not bead blast the bearing housing as thismay damage critical bearing surfaces.
It is permissible to bead blast steel rotating parts.
Always clean components with compressed air afterblasting.
CAUTION
Blasting specific areas for long periods of time
may affect component balance. Protect thread ofturbine wheel assembly.
CAUTION
Do not bead blast the aluminium compressorhousing as this may damage critical surfaces.
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5:8
Major ComponentsAssembly Turbine WheelPlace assembly, turbine wheel (6) on vee block.Position dial gauge on turned surface of shaft atthreaded end. Check dial gauge reading. Where shaft
bend is greater than recommended maximum of0.015 mm (0.0006 in) replace assembly.
CAUTION
Do not attempt to straighten turbine shaft.
Turbocharger Service and Overhaul
Inspection and Testing
Inspect split ring seal, turbine (13)* groove walls forwear. If there is any evidence of wear or damagereplace assembly.
If wear step on ring face exceeds 0.102 mm (0.004 in)replace split ring seal, turbine.
If free gap of ring is less than 2.0 mm (0.08 in) replacesplit ring seal, turbine.
Inspect bearing journals for excessive scratches andwear. Where scratching is excessive or where either
journal diameter is less than recommended minimum of7.53 mm (0.296 in) replace assembly.
Inspect for cracked, bent or damaged blades.
CAUTION
Never attempt to straighten blades.
Replace with new if any damage found.
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5:9
Compressor WheelInspect compressor wheel (7), for cracked, bent ordamaged blades.
CAUTION
Never attempt to straighten blades.Replace with new if any damage found.
Turbocharger Service and Overhaul
Compressor HousingInspect internal profile of compressor housing (8), forscoring damage due to possible contact withcompressor wheel. Check retaining ring, compressorhousing (91) groove is free from deposits.
Return to Component Cleaning if deposits remain.
Replace with new if profile damage is visible.
Ensure position of compressor housing retaining ringgroove has not been compromised by wear.
CAUTIONGood groove and abutment face condition arecritical to integrity of compressor housing tobearing housing joint.
Check bearing housing location pin is not bent or loose.Replace if damaged.
Turbine HousingM8 x 1.25 (13 mm)
Check bearing housing location pin is not bent or loose.Replace if damaged.
Inspect turbine housing (5) profile for damage causedby possible contact with rotor. Inspect outer and internalwalls for cracks or flaking caused by overheating.
Check turbine housing inlet flange flatness is within 0.1mm (0.004 in). Check flange threaded holes with M8 x1.25 thread gauge.
Replace with new if any of above features are noncompliant.
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5:10
WARNING
Always wear safety glasses.
After washing and bead blasting wastegate valvemechanism may remain seized or stiff to operate. If so,
soak mechanism in penetrating oil for approximately 20minutes or period of time recommended by oilmanufacturer.
Access to valve mechanism via turbine housing outletcan be restricted but, with care, soaking withpenetrating oil is possible.
Turbocharger Service and Overhaul
Check wastegate lever arm for evidence of rubbing orcracking. Check lever arm pivot for evidence of fretting
damage, wear or cracking. Check lever arm for crackingand or misalignment due to mechanical damage.
Replace with new turbine housing if damage is visible.
CAUTION
If wastegate valve mechanism shows any fault, itmust be replaced. Using damaged turbinehousings will lead to inferior performance of
turbocharger, and risk of irreparable damage toboth turbocharger and engine.
Radial cracks can occur around valve seat whenturbocharger has been overheated. Use torch to inspectfor cracks when visibility is restricted.
Clamp pair of mole (vice) grips to lever and gently applypressure to rotate lever arm in arc.
If this process does not free valve mechanism, newturbine housing must be fitted.
CAUTION
Extra care must be taken when attempting to freevalve mechanism. Any damage will result in
replacement of turbine housing.
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5:11
Wastegate ActuatorInspect actuator rod end bore which locates on cranklever for elongation. Ovalisation must not exceed 0.50mm (0.020 in).
CAUTION
If actuator shows any fault, it must be replaced.
Turbocharger Service and Overhaul
Bearing HousingAir and Water Cooled Bearing Housing
Oil inlet adapter M10 x 1.25
Oil outlet flange M6 x 1.0
Inspect journal bearing bores for wear and score marks.Replace bearing housing (4) if bore diameter exceeds
maximum of 13.006 mm (0.512 in) or when borescratching is severe.
Check that oil cavity is free from carbon and anyentrained debris that may be the result of failure.Ensure all oil port threads are clean and checked withappropriate thread gauge.
If threads are damaged replace housing (4)
Check oil seal plate, retaining ring groove is clean andhas no debris.
Water Cooled Bearing Housing
Coolant Adapter M8 x 1.25
Ensure all coolant port threads are clean and checkedwith appropriate thread gauge.
If threads are damaged, replace housing (4)
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5:12
Heat ShieldCheck and replace if heat shield (38) is distorted or ifsigns of rubbing or cracking are visible.
Turbocharger Service and Overhaul
Thrust Collar
Check and replace if thrust collar (36) is scored onthrust face or if any cracks are visible.
Small ComponentsOil Slinger
Inspect and replace oil slinger (31) if piston ring groovewalls are scored, damaged or worn.
Check for signs of rubbing and scoring on thrust
surface and replace where damage is severe.If ring faces show any signs of wear replace split ringseal, compressor (16).
If free gap of ring is less than 2.0 mm (0.08 in) replacesplit ring seal, compressor (16) *.
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5:13
WARNING
Always wear safety glasses.
Core Balance
CAUTIONThis turbocharger was manufactured using highspeed core balance process. It must be
re-balanced on reassembly using vibration sortingrig (VSR).
CAUTION
Any attempt to balance rotor using scribe markscould lead to turbocharger and engine failure. Do
not scribe mark any rotor component.
Turbocharger Service and Overhaul
Reassembly
Small high speed turbochargers require new standardof balancing process using proprietary vibration sortingrig (VSR). As results of vibration based tests are rigspecific, balance limits shown in HolsetÕs Service DataSheet s are advisory only. Refer to repair agent towarrant durability, noise and vibration level of specificbalancing process used.
Turbocharger Reassembly
Install new split ring seal, turbine (13) * to assembly,turbine wheel.
Lightly oil journal bearing, turbine (11) * and insert intoposition against inboard retaining ring, bearing (64).
NOTICEProprietary retaining rings, bearing may still befitted following cleaning and inspection. Refer toDisassembly for removal/fitting.They can bereplaced by equivalent circlip.
CAUTION
When fitting circlips always ensure bevelled edgeis facing journal bearing. Premature failure will
result from incorrect orientation.
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5:14
WARNING
Always wear safety glasses.
Place bearing housing compressor face on cleansurface.
Place heat shield (38) on shaft and insert assembly,turbine wheel (6) into assembled turbine end journalbearing. Ensure wheel spins freely by hand rotation.
CAUTION
Align single split ring seal so that gap is
positioned 180 degrees from oil drain flange.
Turbocharger Service and Overhaul
Turn over bearing housing and position in turbinehousing. Ensure that assembly, turbine wheel is looselyretained by hand until it is properly held by turbinehousing. Lightly oil journal bearing, compressor (11) *
and locate into position on assembly, turbine wheelagainst its inboard retaining ring (64).
CAUTION
If alternative circlip features bevelled edge always
face bevel towards bearing.
CAUTION
Take care. Do not damage turbine wheel blades
during insertion into turbine housing.
Insert thrust collar (36)
Install thrust bearing (12) on to location pins. Lightly oilthrust face.
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WARNING
Always wear safety glasses.
Loosely assemble oil baffle (33) to oil slinger (31).
Complete sub-assembly by fitting new split ring seal,turbine (13) * to oil slinger/ oil baffle loose assembly.
Turbocharger Service and Overhaul
Insert oil slinger assembly into oil seal plate (43).
Lightly oil o-ring seal, bearing housing (32) and insert.
Oil seal plate assembly will require finger pressure toovercome o-ring pre-compression and achieve its axiallocation.
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WARNING
Always wear safety glasses.
Use suitable circlip pliers to install retaining ring, insert(66).
CAUTION
Retaining ring must be fitted with chamfered faceupwards away from oil seal plate.
Turbocharger Service and Overhaul
Tap ends of retaining ring (66) lightly with hammer anddrift to ensure that retaining ring is properly located intoits groove in bearing housing.
Remove partly built core from turbine housing andclamp turbine wheel in 12mm 12 point socket located in
suitable jig.Ensure that back face of compressor wheel (7) is cleanand free from damage. Install on to shaft.
Brush locknut face with molycote anti-seize compoundto avoid loss of clamp load during torque tightening.
CAUTION
Always fit new locknut, compressor wheel (61) to
facilitate re-balancing on vibration sorting rig(VSR).
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5:17
M7 LH (10 mm)
Install new locknut, compressor wheel (61) and tightenin two stages to values shown in Service Data Sheet .
NOTICELeft hand thread.
Turbocharger Service and Overhaul
Place turbine housing (5) on clean surface. Placev-band (28) loosely into position on turbine housing.Carefully slide CHRA (2) assembly into turbine housing.Use alignment marks to locate CHRA assembly ontopin located in turbine housing.
CAUTION
Take care. Do not damage turbine blades during
insertion into turbine housing.
CAUTION
Take care. Do not not to bend location pin duringassembly.
M6 (10 mm)
CAUTIONEnsure v-band screw and new locknut (62) areclean and oil free.
Locate v-band to orientation marks. Apply molycoteanti-seize compound to v band fastener threads. Insertscrew and apply new locknut. Torque tighten to valuespecified in Service Data Sheet .
Ensure rotor assembly freely rotates.
Check thrust clearance using dial gauge. Ensureclearance is within MIN/MAX values shown onService Data Sheet .
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5:18
WARNING
Always wear safety glasses.
Check compressor end radial movement using dialgauge. Ensure clearance lies within MIN/MAX TIR
(Total Indicator Reading) values shown onService Data Sheet .
Turbocharger Service and Overhaul
Remove locknut, v-band clamp and carefully extractcore for balancing on vibration sorting rig (VSR) toadvisory limits shown in Service Data Sheet .
CAUTIONBe careful not to bend location pin during
disasssembly and reassembly.
NOTICERefer to nearest Holset Agent for assistance withVSR balancing.
M6 (10 mm)
Relocate balanced CHRA (2) into turbine housing (8)using alignment marks to locate assembly on to roll pin
fixed in turbine housing. Apply molycote anti-seizecompound to locknut, v-band (62). Tighten locknut totorque shown in Service Data Sheet .
Using soft faced hammer, tap v-band clamp three orfour times at equally spaced distances around itscircumference. Re-tighten locknut, v-band (62) to torqueshown in Service Data Sheet .
Lightly oil o-ring seal, compressor housing (41) andinsert.
CAUTION
Always fit new seal on reassembly.
Grease o-ring seal lightly to ensure it stays in positionduring reassembly.
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WARNING
Always wear safety glasses.
Place retaining ring, compressor housing (91) aroundbearing housing. Carefully locate compressor housingover compressor wheel and locate on bearing housingspigot.
CAUTION
Take care. Do not to bend location pin or damagecompressor blades during reassembly.
Turbocharger Service and Overhaul
Turn loose assembly on to compressor housing inletface.
Locate retaining ring over CHRA. Using suitable circlippliers, fit retaining ring.
Tap ends of retaining ring lightly with hammer and driftto ensure that retaining ring is properly located into itsgroove in bearing housing.
CAUTION
Ensure drift does not damage bearing housing.
Ensure rotor assembly rotates freely.
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5:20
Turbocharger Service and Overhaul
Pre-set Wastegate Actuator Reassembly
CAUTION
This range of turbochargers features turbine and
compressor mounted wastegate actuators with
alternative setting procedures.Contact your local approved dealer for correct
replacement actuator kit (74) or bracket kit (136). Itis important to quote correct turbocharger
assembly number, serial number and type toensure supply of correct pre-set actuator.
NOTICERefer to relevant Actuator Reassembly section forrefitting instructions.
NOTICE
Refer to Actuator Bracket Reassembly section forrefitting instructions.
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C i T b T h l i Ltd
Holset HE201W/211W/221WService Repair Manual