Holset HE351CW Series Turbos
Contents
1. 3 1 4 Component Testing and Replacement Service TOOIS ios dene ne pune RAS ba da dd REPE IRR Ed 4 1 On Engine Checks 4 2 Discharge Pipe Removal and Refitting 4 6 Bearing Clearance 4 7 Wastegate Actuation Checks 4 8 Wastegate Actuator Checks 4 9 Actuator Removal 4 10 Wastegate Mechanism Check 4 11 Wastegate Actuator Replacement 4 13 Command Valve Checks 4 16 Command Valve Removal and Refitting 4 16 Command Valve Cleaning 4 17 6 Service Data Sheets HE Range Service Data Sheets 6 1 HE351CW Service Manual Introduction About the Manual The procedures in this manual were developed to instruct in the correct overhaul of the designated Holset turbochargers for optimum performance and minimum maintenance operation How to Use the Manual The manual is split into sections designed to provide service information in a logical sequence The manual contains links to help the user navigate between relevant sections Users who ar2. E 7 E Engine Running Hot Engine Lacks Power Black Exhaust Smoke Blue Exhaust Smoke High Oil Consumption Turbocharger Noisy Oil Leak from Turbine Seal Dirty air cleaner eo e Clean or replace element according to manufacturer s recommendations Restricted compressor intake duct Remove restriction or replace damaged parts as required Restricted intake manifold Refer to engine manufacturer s manual and remove restriction Air leak in feed from compressor to intake manifold eo Replace seals gaskets or tighten fasteners as required Air leak between intake manifold and engine Refer 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 system Remove restriction or replace damaged parts as required e e e e Exhaust manifold cracked gaskets blown or missing Refer to engine manufacturer s manual and replace gaskets or damaged parts as required Gas leak at turbine inlet exhaust manifold joint e e Replace gasket or tighten fasteners as required Gas leak in ducting after turbine outlet e Refer to engine manufacturer s manual and repair leak Restricted turbocharger oil drain line Remove restriction or replace damaged parts as required e e Restricted engine crankcase breather eo eo Refer to eng
3. Hose and clip connections of intake manifold systems must be capable of withstanding the turbocharger pressure ratio V band clamps are preferred and must be used above 3 1 pressure ratio Exhaust systems must be capable of operating at exhaust back pressures of up to 10 kPa 1 5 Ibf in This limit is increased to 13 4 kPa 2 0 Ibf in if a catalytic converter is fitted Exhaust brake applications are permitted to impose 450 kPa 65 3 Ibf in back pressure 6 10 11 12 13 14 15 Oil should be filtered to 10um with efficiency of 60 TWA Time Weighted Average 20 um with efficiency of 8596 TWA Efficiency assessed using ISO Standard 4572 SAE J 1858 The oil quality must be as specified by the engine manufacturer and will be a minimum API SE CD MIL L 2104C specification Improved life can be obtained by using super high performance diesel SHPD oils particularly in industrial applications which use extended oil drain periods Normal oil temperature is 95 5 C 203 9 F It should not exceed 120 C 248 F under any operating condition Any pre lube oil must be clean and meet the minimum CD classification The orientation of turbine housing bearing housing and compressor cover is fixed according to application During installation do not attempt to rotate these components Inclined turbocharger installation is not recommended If an installed angle is necessary oil inlet centreline must be 10
4. 0 H gt D e 2 gt CIO gt d g 7 CIO gt CIO HE351CW Service Manual 1 4 in 28 UNF 1B 7 16 in Where exhaust gas is leaking from turbine housing gt discharge pipe exhaust system joints ensure v band lt fastener torques meet specification Tighten turbine D Gf housing discharge pipe v band locknut to torque specified in Holset s Service Data Sheet Refer to engine manufacturer for details of discharge pipe to exhaust system connection Warning A Always wear safety glasses SAB If leakage persists and where practical disassemble exhaust system pipework Check Marman connections for fretting damage If sealing is compromised replace discharge pipe in accordance with Discharge Pipe Removal and Refitting Air Leakage 25 mm Check for air leaks from command valve EN Tignten command valve in accordance with Command Valve Removal and Refitting If leakage persists remove command valve and replace o rings using service kit comprising 3 radial o rings 27 oe2 Warning Never attempt to check for leaks using air supplied from a running engine If it is possible to check for wastegate actuator rod movement and air leakage on engine follow the checking procedure described later in Wastegate Actuator Checks g SEN E ii
5. 7 Visual Checks Check for cracked bent or damaged compressor wheel blades Replace turbocharger if damaged or bent Caution A Never attempt to straighten blades Component Testing and Replacement 0 4 4 HE351CW Service Manual Where practical check for cracked bent or damaged turbine wheel blades This will require discharge pipe removal where fitted Replace turbocharger if damaged or bent Caution A Never attempt to straighten blades With intake system disconnected from compressor housing it may be possible to check visually for excess bearing axial and radial clearances If in doubt the turbocharger must be removed from engine to check bearing clearance against recommended values shown in Service Data Sheet On engine Command Valve Checks Warning Ensure engine start key is in off postion Refer to Command Valve for checking removing cleaning and refitting Component Testing and Replacement 0 SD 4 5 HE351CW Service Manual Discharge Pipe Removal and Refitting 1 4 in 28 UNF 1B 7 16 in A F On removal of turbocharger from engine place turbocharger compressor end on suitable workbench Mark orientation of V band relative to discharge pipe and turbine housing Loosen and remove V band nut Warning Always wear safety glasses Carefully lift discha
6. Ensure engine start key is in off postion When oil has been found in the compressor housing it may be necessary to remove the command valve for cleaning Refer to Command Valve for checking removing cleaning and refitting oge Or S pa OP Component Testing and Replacement 0 H 4 2 HE351CW Service Manual Gas Leakage Warning A Always wear safety glasses Turbine housing flange leakage will cause soot formation on the flange Check exhaust manifold to flange seal ensuring fastener torque meets engine manufacturer s recommendation Where leaks persist check exhaust flange for cracks Caution A Turbine housings can exhibit cracking when subject to excessive thermal and mechanical loads Cracking of the turbine housing inlet flange and inlet duct generally requires turbocharger replacement Acceptance and rejection guidelines are shown in this illustration If an exhaust gasket is available always ensure that any cracks lie within its sealing area Check turbine housing inlet flange flatness is within O 1 mm 0 004 in before retaining turbocharger for re use Flange Fasteners Clearance Holes Check fastener hole diameter is not more than 1 5 mm larger than the max thread diameter of the fastener Flange Fasteners Threaded Holes M10 x 1 5 Check flange threaded holes with an M10 x 1 5 thread gauge Component Testing and Replacement
7. turbocharger Warning Maintenance or Service procedures which if not correctly followed will result in personal injury or loss of life Note Holset turbochargers can be remanufactured using recovered parts Where it is necessary to dispose of components or whole turbochargers an envornmentally responsible process such as recycling should be used with due regard to local laws Note Holset Service receives many turbocharger returns that are no fault found Before assuming the turbocharger is not performing to specification always refer to the engine diagnostic system Holset s Turbocharger Diagnostic charts and the troubleshooting diagnostic procedures of this manual Warning Turbocharger surface temperature during operation can achieve 700 C 1300 F The HY35W turbocharger weighs up to 9 1kgs 20 1 Ib and is fi tted with external parts that are sensitive to manual handling Caution A This controlled wastegate turbocharger has been factory balanced using a proprietary high speed vibration sorting rig VSR On rebuild it may be balanced using the low speed core balance process but this could affect turbocharger noise level Service overhaul repair must be carried out by Holset Engineering to ensure the system is correctly rebuilt It is important to note that operating a turbocharger with a balance level greater than design limits could cause turbocharger or engine failure Caution A Never remove the wastegate actuator unl
8. The following group of symbols have been used in this manual to help communicate the intent of the instructions When one of the symbols appears it conveys the meaning defined below e 2 gt SE WARNING Serious personal injury or extensive property damage can result if the warning instructions are not followed CAUTION Minor personal injury can result or a part an assembly or the engine can be damaged if the caution instructions are not followed 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 HE351CW Service Manual Introduction Simbolos Espa ol Los simbolos siguientes son usados en estes manual para clarificar el proceso de las instrucciones Cuado aparece uno de estos simbolos su significado se espcifica en la parte inferior e 2 S SE ADVERTENCIA Procedimientos de Mantenimiento o Servicio q
9. degrees from vertical and rotor centreline 5 degrees from horizontal Holset permits oil return pipes 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 integrated connectors To ensure oil returns 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 mm above the maximum oil level of the engine sump pan Crankcase pressure should be limited ideally to 0 8 kPa 0 12 Ibf in but 1 4 kPa 0 20 Ibf in can be accepted by reference to Holset Oil pressure of 150 kPa 20 Ibf in must show at the oil inlet within 3 4 seconds of engine firing to prevent damage to turbocharger bearing system A flexible supply pipe is recommended The minimum oil pressure when the engine is on load must be 210 kPa 30 Ibf in Maximum permissible operating pressure is 500 kPa 72 Ibf in although 600 kPa 88 Ibf in is permitted during cold start up Under idling conditions pressure should not fall below 70 kPa 10 Ibf in Recommended oil flows for the turbochargers are 2 litre min at idle and 3 litre min above maximum torque speed Do not use liquid gasket substances or thread sealant as any excess can enter the turbocharger oil system to obstruct flow Note 100 kPa 1bar 14 5037 Ibf in psi HE351CW Service Manual I
10. exhaust gases to force more air into the engine cylinders Hot exhaust gas energy is used to turn a turbine wheel and shaft At the other end of the shaft is the compressor 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 the most beneficial devices for improving engine performance It performs its job very well as long as it is properly cared for Introduction to Wastegate Turbochargers The need for wastegated turbochargers The wastegate turbocharger on your vehicle s engine is of a very advanced type which varies the effective size of its turbine in response to the driver s demands Under all conditions of driving the turbine wastegate is electronically controlled to change the amount of air supplied to the engine to ensure maximum performance lowest fuel consumption and minimum exhaust emission levels When rapid vehicle acceleration is required the turbocharger will produce air for the engine more quickly than a conventional unit reducing turbocharger lag and giving improved vehicle drivability As the engine and turbocharger run in and eventually start to wear the controlled wastegate and its associated electronic control will change its characteristic to keep to the original performan
11. outdated saved or printed versions and always access the latest information available at www holset co uk When using the manual on line this icon will link to Holset s website to help find your nearest agent for advice and how to order Holset original parts How to Order Holset Original Parts To make sure of optimum performance certain items must be discarded during disassembly and replaced with new 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 component identification section of this manual to help 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 turbocharger s dataplate which will be found on the compressor housing or 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 HE351CW Service Manual Introduction Description and Operation of Turbocharger General Information A turbocharger is a mechanical device which uses the engine s
12. passe de DESMONTAGEM Indica um passo de MONTAGEM Requer inspec o LIMPE a peca ou conjunto Requer Medic o mec nica ou de tempo LUBRIFIQUE a peca 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 medic o EL TRICA Procure em outra sec o deste manual ou em publica o par obter informacdes 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 Conte do 1 10 HE351CW Service Manual Component Identification Turbocharger Identification H Dataplate Note 35XXXXX Dataplates may be fitted NN CHE to the wastegate actuator ad 73 or to the compressor housing 8 The e information from the dataplate must be quoted for service and parts support HE351CW 2 1 HE351CW Service Manual Component Identification 0 Installation Options 2 2 HE351CW Service Manual Component Identification Exploded View HE351CW H Note Exploded views represent a generic build standard Parts may be added or subtracted in specific applications 2 3 HE351CW Service Manual Component Identification Component List HE351CW H Item No Descriptio
13. HOLSET TURBOCHARGERS N WARNING ge Turbochargers can be hazardous when not used HR as specified by the manufacturer To prevent damage and personal injury Always use the turbocharger part number specified by the engine manufacturer Use only in applications approved by the engine manufacturer 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 engine manufacturer s instructions Use only approved spare parts For advice on the safe use of turbochargers contact www holset com Copyright 2008 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 HE351CW Service Manual Foreword Foreword This publication was written to assist with turbocharger installation maintenance and overhaul It is not a warranty of any kind express 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 H
14. Suitable alternative hose clamps can be used 4 15 HE351CW Service Manual Command Valve Valve Check Warning A Ensure engine start key is in off postion Do not remove command valve from turbocharger at this stage To check electrically use a multi meter to check resistance between pins 1 and 2 The resistance for the 12 V command valve should be a minimum of 6 0 Ohm at 20 C Where minimum resistance is not achieved replace in accordance with Command Valve Removal and Refitting A service kit 169 is available from your approved Holset service agent Valve Removal and Refitting 25mm Warning Always wear safety glasses Loosen command valve using open ended thin section spanner Warning If there is any possibility that the seal has been subject to fire always wear neoprene gloves when handling Unscrew valve ensuring not to damage three o ring seals flying lead or connector All command valves which have passed the electrical resistance check should be cleaned in accordance with Command Valve Cleaning Ensure cleaned or replacement command valve 169 is fitted with three o ring seals 27 before inserting into compressor cover screwed location An o ring service kit is available from your approved Holset service agent Insert command valve carefully avoiding damage to o ring seals Hand tighten command valve Using open ended thin section spanner continue to tighten by rotating
15. and check that there are no leaks obstructions of air oil coolant gas under pressure Check that no hose or connection deforms under normal operation Before switching off the engine leave it running at idle speed for at least 1 minute to cool the turbine HE351CW Service Manual Introduction Symbols Symbole Deutsch In diesem Handbuch werden die folgenden Symbole verwendet die wesentliche Funktionen hervorheben Die Symbole haben folgende Bedeutung e 2 gt SE WARNUNG Unterhaltungs und Wartungsverfahren m ssen genau befolgt werden da ein Nichtbeachten zu Personensch den oder t dlichen Verletzungen f hrt ACHTUNG Falls Unterhaltungs und Wartungsverfahren nicht genau beachtet werden kann der Turbolader dadurch besch digt oder zerst rt werden 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 da8 die AUSWUCHTMARKEN an der Rotor Baugruppe richtig ausgerichtet sind Elektrische MESSUNG DURCHF RHREN Weitere Informationen an anderer Stelle bzw in anderen Handb chern Schutzkleidung muB immer getragen werden Deutet an daB Teile schwer sein k nnen Website Verzeichnis mit Ihrem n chsten Holset H ndler Gehe zu Inhalt HE351CW Service Manual Introduction Symbols English
16. ce and emission levels over a wide range of ambient temperatures and altitude The importance of correctly servicing the wastegate actuator mechanism A wastegate turbocharger requires accurate setting at point of manufacture It is very important to adhere to setting limits when servicing the turbocharger as failure to do so could result in turbocharger or engine failure Effects of wrong setting Possible consequences if the actuator is set to give a boost pressure 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 risks damage to engine pistons Possible consequences if the actuator is set to give a boost pressure 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 HE351CW Service Manual Introduction Notes Cautions and Warnings Notes Cautions and Warnings are used in this manual to emphasise important or critical instructions Note Information which is essential to highlight Caution A Maintenance or Service procedures which if not strictly followed will result in damage or destruction of the
17. e by turning jam nut anti clockwise counter clockwise Remove and discard tie wrap and spacer piece Continue turning jam nut in the same direction and torque tighten against end link to value shown in Service Data Sheet New pre set actuator kits 74 may be supplied with a tamper resistant break off nut 143 instead of a jam nut 128 to secure the end link in its correct pre set position To install a tamper resistant actuator 1 Slacken the shear nut from the spacer spine 2 Continue to turn the nut until it contacts the pre set end link 3 Continue tightening until the hex flats break off leaving only the cone section in tight contact with the end link YA eo pa ob VA eo D g IC 9 Component Testing and Replacement 0 HE351CW Service Manual Component Testing and Replacement 25 mm Refit command valve in accordance with Command Valve Removal and Refitting Warning Always wear safety glasses Caution A Before mounting turbocharger on engine check for full and free wastegate movement previously described in Wastegate Actuator Checks Refit the air supply hose between actuator and command valve with new hose clamps 75 Clamps should be crimped closed using pinsers Crimp gap will vary due to spring back and hose type but will not be CS less than 0 6 mm 0 0025 in
18. e unfamiliar with navigating in PDF documents are refered to Navigating in PDF documents in the Adobe Acrobat Reader 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 a major turbocharger malfunction This section is not available for the HE351CW turbocharger range at the present time 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 organised according to the steps needed to most easily and correctly maintain the operation of the turbocharger Users are 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 data are active only when the user is connected to the Internet Chapter 6 has an expiry date to encourage users to discard
19. ead connector in cleaning fluid Always remove o ring seals before cleaning Dry the valve using compressed air gt Y E E erc Component Testing and Replacement 0 H 4 17 HOLSET TURBOCHARGERS Cummins Turbo Technologies Ltd Aftermarket Division Croset Avenue Huddersfield West Yorkshire HD1 6SE www holsetaftermarket com 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 Part No 4029546 Rev 02 Ref JV KD Effect date 11 08 Technologies Copyright 2008 Cummins Turbo Technologies Ltd All rights reserved S Turbo
20. ed braking Failed actuator diaphragm Replace using correct Actuator Service Kit e e Seized wastegate valve in turbine housing Free valve in accordance with details in the appropriate Holset publication replace eo complete turbine housing sub assembly Leaking actuator hose Replace hose and clips e e Wastegate mechanism set incorrectly Contact your approved Holset agent for correct setting procedure e Actuator rod not moving 1 Actuator rod not moving Check for system air leaks and change clamps and hoses as appropriate 2 Actuator rod not moving but OK on separate air supply e Check command valve in accordance with Holset service instructions 3 Actuator rod not moving and not OK on separate air supply Suspect seized wastegate valve in turbine housing Free valve in accordance with Holset service instructions If valve cannot be freed replace turbocharger 4 Failed actuator diaphragm If wastegate valve is free command valve checked OK and there are no leaks but actuator rod does not move replace actuator using correct Actuator Service Kit Actuator loose or damaged Refer to ECU diagnostics for possible fault code data Check for damage to actuator bracket and fasteners If mechanical installation is OK check actuator movement If full o and free movement not confirmed replace actuator If partial movement with new actuator replace turbocharger Oil feed and return lines or adaptors leaking Chec
21. en abused or overheated Component Testing and Replacement 0 H g d EZ OLD 9 4 11 HE351CW Service Manual After freeing wastegate valve mechanism always check for damage to cross shaft and bearings Where the cross shaft axial or radial clearance is high replace turbocharger Lever arm pin can be worn by partial seizure of the valve mechanism Scoring may be caused by arduous local environmental conditions Valve mechanism seizure can also lead to elongation of the rod end bore which locates on the lever arm pin This must not exceed 0 50 mm 0 020 in Caution A If the actuator shows any fault it must be replaced Component Testing and Replacement 0 H MOD 4 12 HE351CW Service Manual Wastegate Actuator Replacement Caution A A Contact your local approved agent for the correct replacement actuator kit 74 It is important to quote the correct turbocharger assembly number serial number and type from the dataplate to ensure the supply of the correct pre set actuator Note When refitting existing actuator the end link will be locked in the correct setting Thread new end link several turns on to the shaft of the new pre set actuator assembly Hold the actuator assembly with the spine of the spacer piece upright Rotate the valve mechanism lever arm to close the wastegate valve pushed toward
22. ess the actuator is to be renewed Never adjust the link rod of an assembled wastegate turbocharger The link rods are set by the O E supplier to precise limits which must be adhered to maintain performance and emissions levels Always check that the actuator and wastegate mechanism is still in good working order before proceeding with disassembly of your wastegate turbocharger Warning A Some parts are manufactured in fluoroelastomers eg Viton or similar that require special treatment in the case of repair and service after fire HE351CW Service Manual Introduction Installation Data 1 5 Holset Service receives many turbocharger returns 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 this manual to make all the recommended health checks It is important that intake and exhaust systems are fitted in accordance with the recommendations of the Equipment and Engine manufacturers Limiting mass inertia loading is critical to turbocharger whole life operation Maximum engine vibration input must not exceed 10g The air filter must remove particles greater than 5um at an efficiency of 95 and be of sufficient capacity to match the air consumption of the engine Recommended filters should always be used with a pressure drop indicator Intake systems must be capable of withstanding depressions up to 6 9 kPa 1 0 Ibf in
23. fety glasses Removal of an original hose clamp is a 3 stage operation Place the turbocharger on a suitable workbench 1 Using a small flat screwdriver carefully unhook the location barb 2 Grab the free end of the clamp with long nose pliers to open the crimp 3 Pull the flexible hose from the actuator spigot Discard the hose clips 75 Warning Avoid touching the wastegate rod end area as finger injury may result from sudden movement of the assembly when air pressure is applied Connect and secure the hose from the regulated compressed air supply to the actuator spigot Carefully apply pressure to the actuator from the regulated compressed air supply Max 3 bar 45 Ibf in and check for actuator movement Actuation Checks If rod does not move check wastegate actuator for air leaks If air leak is found replace actuator in accordance with Wastegate Actuator Replacement If no air leak is found and rod does not move failure may be result of mechanical failure of actuator or seizure of wastegate valve mechanism Dissconnect actuator and check in accordance with Wastegate Actuator Check ef Component Testing and Replacement 4 8 HE351CW Service Manual Wastegate Actuator Check Warning Always wear safety glasses Using a small flat screwdriver carefully remove the end link retaining clip Caution A Do not rotate actuator rod rela
24. ine manufacturer s manual clear restriction Turbocharger bearing housing sludged or coked Change engine oil and oil filter overhaul or replace turbocharger as required Fuel injection pump or fuel injectors incorrectly set Refer to engine manufacturer s manual and replace or adjust faulty components as required Engine valve timing incorrect Refer to engine manufacturer s manual for correct settings and adjust as required Worn engine piston rings or liners Refer to engine manufacturer s manual and repair as required e e e Burnt valves and or pistons e e e e e e Air leak in feed from air cleaner to compressor e eplace seals gaskets or tighten fasteners as required e e e Refer to engine manufacturer s manual and repair as required Excessive dirt build up on compressor wheel and or diffuser vanes Clean in accordance with details in the appropriate Holset publication e oo Find and propia failure repair or replace turbocharger as necessary 3 1 HE351CW Service Manual Troubleshooting and Diagnosis Fault Finding Chart controlled Wastegate Intermittent engine braking Engine does not run smoothly Low power at low engine speed Intermittent low power d o 3 a x a o amp Engine Overheats Turbocharger noisy Poor acceleration Reduc
25. k oil feed and return pipes and adaptors for leakage Check O ring seals and replace if necessary Tighten adaptors and if leak persists replace failed adaptors or pipes using Holset recommended parts Bearing housing damaged If o ring or connector replacement does not resolve an oil leak the bearing housing 0 tappings may be damaged requiring replacement of the turbocharger Intermittent control valve drive signal Refer to ECU diagnostics for possible fault code data Check control valve connection to o ECU If control valve condition at either O V or vehicle battery voltage is incorrect or if intermittent fault persists replace control valve whilst referring to engine manual No boost pressure signal P2 If the ECU diagnoses a boost pressure signal error refer to engine manual e e No air inlet temperature signal T2 If the ECU diagnoses an air inlet temperature signal error refer to engine manual e e Oil feed and return lines or adaptors leaking Check oil feed and return pipes and adaptors for leakage Check O ring seals and replace e if necessary Tighten adaptors and if leak persists replace failed adaptors or pipes using Holset recommended parts Bearing housing damaged If o ring or connector replacement does not resolve an oil leak the bearing housing o tappings may be damaged requiring replacement of the turbocharger 3 2 HE351CW Service Manua
26. l Component Testing and Replacement Service Tools H The following special tools are recommended to perform procedures in this manual The use of these tools is shown in the appropriate procedure Part No Tool Description Tool Illustration Torque Wrench Dial Gauge and Dial Gauge Adapter Regulated air supply 4027204 E Clip Tool Caution VAN All Service and Maintenance settings are shown in Holset s Service Data Sheet It is essential that these settings are used Common tools found in mechanic s tool box not included 4 1 HE351CW Service Manual On Engine Checks Oil Leakage Bearing Housing M12 x 1 5 19 mm Pipe Fitting 11 16 16 UN 19 mm Warning The oil inlet is pressurized and no service action should be taken with the engine running Replacement seals and adapters should be fitted without sealant as this can contaminate the oil Torque tighten adaptor to value shown in Service Data Sheet It is important to avoid kinked pipes during servicing and subsequent operation M8 x 1 25 Warning Outlet oil is hot and no service action should be taken with the engine running Replacement gaskets should be fitted without sealant as this can contaminate the oil Torque tighten flange fasteners to value specified by engine manufacturer All outlet pipes should be free flowing without kinks and sharp bends and decline at an overall angle not less than 30 degrees below the horizontal Warning A
27. n Quantity 28 V band clamp turbine 1 62 Locknut V band 1 80 Discharge pipe 1 74 Actuator kit comprising 73 Actuator 1 75 Hose clamp 2 76 End link assembly 1 77 End link retaining clip 1 81 Hose 1 83 Locknut actuator 2 128 Jam nut 0 1 143 Break off nut 0 1 93 Gasket oil outlet 1 113 Adaptor Oil inlet 1 114 O ring seal oil inlet 2 Command valve kits comprising Command valve assembly comprising 169 Command valve 27 O ring seal 3 Conduit convolute Tape Command valve service kit comprising 27 O ring seal 3 Note Exploded views may not contain all listed components 2 4 HE351CW Service Manual Component Identification Purchasable Service Tools H Service Tools The following special tools can be purchased from your local Authorised Repair Location The use of these tools is recommended and where necessary they are shown in the appropriate service procedure Part No Tool Description Tool Illustration 3575186 Circlip Pliers 4027202 Wastegate Air Feed Adapters 4027203 Wastegate Air Feed Adapters 4027204 E Clip Tool Caution A All Service and Maintenance settings are shown in Holset s Service Data Sheet It is essential that these settings are used Common tools found in mechanic s tool box not included 2 5 HE351CW Service Manual Troubleshooting and Diagnosis Fault Finding Chart an Applications Cyclic Sound from the Turbocharger Oil Leak from Compressor Seal 7 e a 7 ra
28. nd link This setting is critical to actuator performance After removal of hose clamp and hose lift the actuator away from the bracket until the studs clear the location holes Discard hose clamps 75 To replace actuator refer to Wastegate Actuator Replacement Component Testing and Replacement 0 H 4 10 HE351CW Service Manual Wastegate Mechanism Checks Carefully move the lever arm up and down If the arm moves freely by hand then re check for movement of actuator rod If the lever arm is seized the turbocharger will require replacement However it may be possible to free the lever arm Soak wastegate valve and lever mechanism in penetrating oil Warning A Always wear safety glasses Caution A Extra care must be taken when attempting to free the valve mechanism Any damage will result in the replacement of the turbine housing Clamp a pair of quality mole vice grips to the lever and gently apply pressure to rotate the lever arm in an arc If this process does not free the valve mechanism a new turbocharger must be fitted Caution A If the wastegate valve mechanism shows any fault the turbocharger must be replaced Using damaged turbine housings will lead to inferior performance of the turbocharger and risk of irreparable damage to both turbocharger and engine Radial cracks can occur around the valve seat when the turbocharger has be
29. ne manufacturer s recommendation Assemble the air intake and boost outlet connections Check that the connections are secure and will not leak in use Check the exhaust system is fitted using the original mounting arrangement provided by the equipment manufacturer Always re fit any supports brackets back in position to ensure the system is correctly supported Assemble the exhaust system to the turbine housing outlet Check that the gasket connection is secure and will not leak in use Assemble any coolant pipes and check that the connections are secure without obstruction and will not leak in use Assemble the turbocharger oil inlet pipe and check that the connection is clean secure and will not leak in use Connect the air pipe from the command valve to the wastegate actuator ensuring the pipe bore is clean and dry before fitment Check all clamps and fasteners are correctly tightened to the torque recommended by the equipment manufacturer Make the electrical connection between command valve and engine control module ECM Make any ECM checks recommended by the engine manufacturer Crank the engine WITHOUT firing until engine oil flows out of the turbocharger drain flange Assemble the oil drain pipe and check that the connection is secure without obstruction and will not leak in use Start the engine and run at idle speed for approximately 1 minute so that the oil supply system is fully operational Accelerate the engine
30. ntretien qui si elles ne sont pas observ es strictement auront pour r sultat de causer des d g ts au turbocompresseur ou de conduire sa destruction Indique une op ration de DEPOSE Indique une op ration de MONTAGE L INSPECTION est n cessaire NETTOYER la pi ce ou l ensemble EFFECTUER une MESURE m canique ou de temps GRAISSER la pi ce ou l ensemble Indique qu une DIMENSION DE CLE ou D OUTIL sera donn e SERRER un couple sp cifique S assurer que les rep res d quilibrage sur l ensemble de rotor sont align s EFFECTUER une MEASURE lectrique Se reporter un autre endroit dans ce manuel ou une autre publication pour obtenir des information 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 l agent Holset le plus proche Aller au sommaire HE351CW Service Manual Introduction S mbolos Portugu s Os s mbolos a seguir ser o utilizados neste manual para facilitar a comunica o das instruc es e seue significados est o d scritos abaixo e 2 gt Os procedimentos de ou Servigos que forem seguidos correctamente resultar o em ferimentos pessoais ou riscos de vida AVISO Os procedimentos de Manuten o ou Servi o que n o forem rigorosamente seguidos resultar o em danos ou destrui o do carregador turbo Indica um
31. ntroduction Installation Checklist 1 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Always understand why the original turbocharger needs replacing before fitting another unit Check the turbocharger dataplate to ensure the Part No is correct for the engine application Check the engine exhaust intake and aftercooler systems are clean and without obstruction i e free from oil gasket pieces dust dirt carbon or foreign objects Replace the oil and air filters using replacement parts specified by the equipment manufacturer Change the engine oil using the type specified by the engine manufacturer Check that the turbocharger oil inlet and drain pipes and connectors are clean free from obstruction and will not leak under pressure Before re installing flexible pipes always ensure any burnt on lacquer or other adhered material is removed from internal bores If in doubt always fit new pipes Check that the coolant pipes of water cooled bearing housing applications and connectors are clean free from obstruction and will not leak under pressure To pre lube the turbocharger bearings pour some clean engine oil into the oil inlet and rotate the turbocharger rotor assembly by hand Check that the exhaust manifold flange is flat and undamaged Mount the turbocharger on the flange and check that the turbine inlet gasket fits properly without obstructing the gas passages Torque fasteners to engi
32. olset 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 HE351CW Service Manual Table of Contents Table of Contents 1 Introduction About the Manual xd Re aber 1 1 How to Use the 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 Warnings 1 3 Installation Data irl al 1 4 Installation Checklist 1 5 Symbols esd sos hy eave ten e ota le iter Era tow 1 6 2 Component Identification Turbocharger Identification 2 1 Dataplate and CHRA Core of Turbocharger 2 1 Installation Options A OM pe ie 2 2 Exploded Views 2 3 Component List sa sine o eU E VERE ed tee Rie 2 4 Purchasable Service Tools 2 5 3 Troubleshooting and Diagnosis Fault Finding Chart
33. rge pipe off turbine housing ensuring that the location pins are not damaged Ensure discharge pipe is fitted with 2 roll pins for location into mating holes in turbine housing Loosely assemble V band on to turbine housing in correct orientation Carefully locate discharge pipe on to turbine housing using orientation marks to ensure roll pins engage correctly in location holes Place V band in position and torque tighten to value shown in Service Data Sheet SS OS Component Testing and Replacement 4 6 HE351CW Service Manual Bearing Clearance Secure the turbine housing and check the axial clearance at compressor impeller nose using a dial gauge Ensure clearance is within MIN MAX values shown on Service Data Sheet If axial clearance does not meet specification replace the turbocharger Check the radial movement at compressor impeller nose using a dial gauge Ensure movement is within MIN MAX TIR Total Indicator Reading values shown on Service Data Sheet If radial movement does not meet specification replace the turbocharger Component Testing and Replacement 4 7 HE351CW Service Manual Wastegate Actuation Checks Caution A Do not remove turbocharger from engine unless an actuator check is impractical due to space or access limitations or where an on engine check has shown a problem exists Warning A Always wear sa
34. s the compressor end Fit end link over the lever arm pin Attempt to slide the actuator over its retaining bracket If the actuator fouls on the bracket or there is significant clearance between bracket and actuator base actuator rod length requires adjustment Note Do not fit the wastegate studs to the bracket at this stage To adjust the length of the actuator assembly remove from the turbocharger Rotate the end link to shorten or lengthen the rod as appropriate Re fit until the underside of the actuator will just fit over the bracket mounting face with less than 0 5 mm 0 020 in gap Caution A Do not apply force to push the actuator on to the mounting face of the bracket The rod length setting is correct if by rotating end link clockwise by a half turn the actuator body fouls on the bracket Component Testing and Replacement 0 H 4 13 HE351CW Service Manual M6 x 1 10 mm Remove the actuator assembly from the lever arm ensuring that the end link does not rotate Fit actuator mounting studs into their locating holes or slots in the bracket Fit both actuator mounting nuts and torque tighten to the value shown in the Service Data Sheet Warning Always wear safety glasses Re fit end link to the lever arm pivot pin Fit new e clip using special tool Part No 4027204 to retain rod end on pin 5 16 24 UNF 2B 1 2 in Loosen spacer piec
35. through 17 degrees Where a calibrated torque wrench is available with suitable spanner detail refer to Service Data Sheet for torque setting Fit split conduit convolute around electric cables and secure with 4 pieces of tape at ends and equally spaced along length RY Sy amp Component Testing and Replacement HE351CW Service Manual Valve Cleaning Warning Always wear safety glasses The command valves uses turbocharger compressed air as input pressure The air supply is taken from the centre of the air stream so dirt build up should be minimal and restricted to soft carbon deposits It is still advisable to clean air passages before refitting the valve Warning Always remove o ring seals before cleaning If there is any possibility that the seal has been subject to fire always wear neoprene gloves when handling Mechanical cleaning of the valve probe can be achieved using either a 1 mm diameter steel wire or if a welding torch cleaning set is available a probe of the same diameter Caution A Welding torch cleaners are abrasive Do not damage valve probe bore during any mechanical cleaning process Use compressed air to purge the valve passages of loose debris The command valve can be cleaned by soaking the valve in a non corrosive low flash point metal cleaner or using an ultrasonic cleaning bath Caution A Do not submerge flying l
36. tive to actuator as this can damage actuator internal components Warning The rod may retract very quickly when freed from lever arm Keep fi ngers away from mechanism Gently apply a small amount of air to the actuator and when if the rod end moves carefully slide the end link off the valve lever arm If the actuator rod does not move a screw driver may be required to prise the end link off the lever arm Apply 300 kPa 45 Ibf in to the actuator If actuator rod does not move refer to Actuator Removal If actuator rod does move check wastegate valve mechanism according to the procedure in Wastegate Mechanism Check Component Testing and Replacement 0 H A SN gt 4 9 HE351CW Service Manual Actuator Removal Warning A Always wear safety glasses Using a small flat screwdriver carefully remove the end link retaining clip Caution A Do nat rotate actuator rod relative to actuator as this can damage actuator internal components Gently apply a small amount of air to the actuator and when if the rod end moves carefully slide the link end off the valve lever arm If the actuator rod does not move a screw driver may be required to prise the link end off the lever arm Warning The rod may retract very quickly when freed from lever arm Keep fingers away from mechanism M6 x 1 10 mm Remove actuator lock nuts Caution A Do not adjust the rod e
37. ue al no seguirse resultar n en da os personales o p rdida de vida ATENCION Procedimientos de Mantenimiento o Servicio que al no seguirse al pie de la letra resultar n en el da o o la destrucci n del turbosobrealimentador 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 mec nica o del tiempo LUBRIQUESE la pieza o el montaje Indica que se dar una LLAVE DE TUERCAS o el TAMA O DE HERRAMIENTA APRIETESE hasta un par torsor especifico Ceri rese de que est n alineadas las marcas de balance en el rotor EJECUTESE una MEDICION el ctrica Para informaci n adicional refi rase a otro emplazamiento de este manual o a otra publicaci n anterior 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 Ira la tabla de materias HE351CW Service Manual Introduction Symboles Francais Les symboles suivants sont utilis s dans ce manuel pour aider communiquer le but des instructions Quand l un de ces symboles apparait il voque le sens d fini ci dessous gt gt 2 gt ATTENTION DANGER Proc dures de maintenance ou d entretien qui si elles ne pas observ es correctement auront pour r sultat des l sions corporelles ou un d c s MISE EN GARDE Proc dures de maintenance ou d e
Download Pdf Manuals
Related Search