Holset HX55V Service Manual - Genuine Holset Turbochargers
Contents
1. ID PAY LAN QE Apply 5 bar air Fit the setting tool into position AN Actuator Replacement Tighten the caphead screw 120 to the required torque Release the air supply and remove the hose from the actuator spigot Page 21 Speed Probe Replacement Page 22 Speed Probe Replacement Service Tools The following special tools are recommended to perform procedures in this manual The use of these tools is shown in the appropriate procedure These tools can be purchased from your local Authorised Repair Location Part No Tool Description Tool Illustration Special Service Tool S Modified 14mm Long Socket Torque Wrench Component Disassembly and Assembly Service Tools Page 23 Component Disassembly and Assembly Service Tools The following special tools are recommended to perform procedures in this manual The use of these tools is shown in the appropriate procedure These tools can be purchased from your local Authorised Repair Location Part No Tool Description Tool Illustration 56662 Circlip Pliers 56664 Circlip Pliers Dial Gauge Torque Wrench Disassembly Component Disassembly and Assembly Page 24 Disassembl Ge Note Denotes a part which is included in the basic overhaul kit Before disassembling the turbocharger scribe the parts listed belo2. Caution Care should be taken not to score the A assembly turbine wheel shaft Oe Carefully remove and discard the two piston ring seals 13 Place the bearing housing on a flat surface and using circlip Ge pliers Part No 56662 remove the insert retaining ring 66 D R Using two flat screwdrivers gently remove the oil seal plate 43 Component Disassembly and Assembly Remove the oil slinger 31 Remove and discard the piston ring seal 16 Remove and discard the O ring seal 32 Remove the oil baffle 33 Disassembly Page 27 Ra Disassembly Page 28 Component Disassembly and Assembly R Remove the thrust bearing 12 Ge Remove the thrust collar 36 Using circlip pliers Part No 56664 remove and discard the two circlips 64 and the journal bearing 11 from the compressor end Component Disassembly and Assembly Cleaning Page 29 Cleaning With the turbocharger completely dismantled for overhaul soak all the components in a non caustic metal cleaner to loosen deposits Bead blast the turbine housing if chemicals do not clean sufficiently On aluminium paris a bristle brush can be used Never use a wire brush or metal scraper on any turbocharger component Ensure that all the parts are finally cleaned with an air jet especially drilled passages and machined apertures Turbine Wheel In the
3. turbine and its associated electronic control will change its characteristic to keep to the original performance and emission levels over a wide rage of ambient temperatures and altitude The bearing housing of your turbocharger contains an internal water cooled jacket The purpose of this is to reduce the running temperature of the electronic speed probe and also to reduce the high temperatures produced when the engine is switched off after being heavily loaded The addition of this water cooling has meant that there are two extra pipe connections to the turbocharger to bring water to the housing and to take it away It is important to observe the correct installation of these pipes so that the circulation of the water is in the correct direction or the effectiveness of the cooling system will be lost and severe damage may result The connections of the pipes into the bearing housing are sealed with and o ring and if the water connections to the housing are removed a new o ring seal must be used for re assembly Table of Contents Page 3 Table of Contents Introduction SA nee ea tute n eua Cd El e dl dada dan annee E RR dia tan le 4 About th Manual 4 How to Use the Manual iot Rent ee a odiada 4 Fault FndNg Oaxaca ld ea 5 liuc tina dada 6 Component Identification Turbocharger Identifi
4. Tool Illustration Air Supply Special Service Tool 5mm Hexagon Key Allen Key 7 16 Inch 11mm Spanner Vernier Gauge Page 18 Ge Actuator Replacement Before attempting to overhaul your turbocharger it is reccomended that you remove the actuator 74 and link end adjuster 76 to do so follow the process below Identify the required setting dimension this will be stamped on the bearing housing in the position shown Write the dimension down and keep itin a safe place This setting will typically be between 58 and 59mm however any decimal places must be noted Apply air pressure Using allen key slacken off cap head screw 120 and remove end adjuster 76 Remove 2 x actuator locknuts 83 Remove actuator from bracket Actuator Replacement Service Tools Page 19 Fitting Original or New Actuator Set the vernier gauge to the correct setting dimension as noted in step 1 eg 58 773 Carefully set the length of the service tool using the set dimension of the vernier gauge Fit the actuator and tighten the 2x locknuts 83 to the required torque Fit the link end adjuster 76 in to position
5. engine provides improved engine performance lower exhaust smoke density improved operating economy altitude compensation and noise reduction 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 itis properly cared for About the Manual The procedures in this manual were developed to instruct in the correct overhaul of the Holset HX55V turbocharger to provide for the optimum performance and minimum of maintenance operation How to Use the Manual This manual is organised according to the steps needed to most easily and correctly overhaul the Holset HX55V turbocharger In the unlikely event of turbocharger malfunction please check the Fault Finding Chart to identify potential causes before attempting disassembly To make sure of optimum performance certain items must be discarded during the disassembly operation and replaced with new for re assembly These items are indicated in the disassembly section with the use of a symbol Allitems showing a are available in a basic HX55V overhaul kit Contact your local agent for part number and availability Warning This turbocharger may have been manufactured using the core balance process and therefore MUST be check balanced on rebuild A core balanced turbocharger will not have any co relation marks on the thrust collar or oil slinger and also may not have co relation marks on the end of the
6. event of carbon build up it may be necessary so carefully blast the Piston Ring Groove area of the turbine wheel using low grade shot medium Caution Shot Blasting specific areas for long periods of time may effect component balance The surface adjacent to the turbine and compressor wheels on the stationary housings must be clean smooth and free from deposits Inspection Caution Do not attempt to straighten the turbine shaft a Place the shaft on a vee block using a dial gauge rotate the turbine wheel and check for movement on the dial gauge Replace the assembly turbine wheel if it is bent Max Shaft Bend Allowed 0 025 mm 0 001ins Shaft Bend mm in 0 025 Max 0 001 Major Components Assembly Turbine Wheel 6 b Inspect the piston ring groove walls for wear Turbine Wheel Piston Ring Groove mm in ID Single Ring 1 664 MIN 0 0665 Twin Ring 3 538 MIN 0 1393 c Inspect the bearing journals for excessive scratches and wear Minor light scratches may be tolerated Assembly Turbine Wheel Journals mm in 3 538 MIN 0 1393 d Inspect for cracked bent or damaged blades but DO NOT ATTEMPT TO STRAIGHTEN BLADES Turbine Housing 5 Inspect the profile for damage caused by possible contact with the rotor Check all threads for damage Inspect the outer and internal walls for cracks or fla
7. on the shaft Install the thrust collar 36 Using clean engine oil lubricate the thrust bearing 12 Install the thrust bearing Assembly Page 35 Assembly Page 36 Component Disassembly and Assembly Install the oil baffle 33 into the oil seal plate 43 Ay Apply a small amount of engine oil to the O ring seal 32 and place into position pay Fit the new piston ring seal 13 to the oil slinger 31 SD Ay Install the oil slinger 31 into the oil seal plate 43 EB ger 31 plate 43 ew Component Disassembly and Assembly Caution Align the balance marks on the oil slinger 31 with that on the shaft end Install the oil seal plate 43 into the bearing housing 4 Genily tap the oil seal plate 43 with a soft hammer to seat in position Use circlip pliers Part No 56662 to install the retaining ring 66 Align the balance marks and install the compressor wheel 7 PAY Assembly Page 37 lt Q SB Thee e Assembly Page 38 q lt Q N QE Component Disassembly and Assembly Caution Ensure that the balance marks are aligned on the compressor wheel and the shaft 13mm Note Left hand thread Install the compressor wheel locknut 61 and tighten to the torque value Tor
8. BLY 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 aWRENCH 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 Introduction Symbols Page 7 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 AA FOMOSBD gt C gt amp ES ADVERTENCIA Serios da os personales o da o a la propiedad puede resultar si las instrucciones de Advertencia no se consideran PRECAUCION Da os menores pueden resultar o de piezas del conjunto o el motor puede averiarse si las instrucciones de Precauci n no se siguen 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 al
9. HX55V oervice Repair Manual Copyright 1998 Holset Engineeri Foreword This publication was written to assist field personnel with basic overhaul and rebuilding of the Holset HX55V turbocharger The specifications and rebuild information in this manual is based on information in effect at the time of printing 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 approved dealer 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 Advantages of Variable Geometry Turbochargers The turbocharger on your vehicle s engine is of a very advanced type which changes the size of it s turbine in response to the drivers demands In this way under all conditions of driving the turbine through its electronic controls changes the amount of air supplied to the engine to ensure maximum performance lowest fuel consumption and minimum exhaust emission levels During a sudden acceleration the turbocharger will produce air for the engine much quicker than a convention unit thus eliminating turbocharger lag and giving improved truck derivability In addition as the engine and turbocharger are run in and eventually start to wear the combination of this variable
10. TISSEMENT De graves l sions corporelles ou des dommages materials consid rables peuvent suvenir si les instructions donn es sous les rubriques Avertissement ne sont pas suivies ATTENTION De petites l sions corporelles peuvent survenir ou bien une pi ce un ensemble ou le moteur peuvent tre endommag s si les instructions donn es sous les rubriques Attention ne sont pas suivies 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 REPERES 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 Symbols Introduction Page 10 S mbolos Portugu s Os s mbolos a seguir ser o utilizados neste manual para facilitar a comunica o das instru es e seue significados est o d scritos abaixo ATEN O Se as instru es n o forem seguidas h possibilidade de ocorrer s rios danos pessoais e materials CUIDADO Danos aos componentes ao conjunto ou ao motor ou mesmo pequenos danos pessoais podem ocorrer se as instru es n o forem se
11. cation sise 11 COMPU Ra ane TOR DD eee le een een 12 Exploded VIEW ADA eine 13 Optional K xo nn 016 nL n E CUPFEHRRFEUEPFTRRERSERRFTRERFEURFFTREFEUFRFRRFNLBURRRINEPUEURFIILEFEUEEEIEFEUBRRHETEFSPERETITEFEUREREIETEUEHHFFERGERFFEEFSEUERFLNEFEUERERELFERE 14 Actuator Inspection Replacement ussuussnnseseenennnnnneennnnnnnenennnnnnnnnnnnnnnnnnennnnnnnnnnnnnsnnnnnnnnnennnnnnnnsnnnnnnnsnnannnnnnsnnnnn 15 Speed Probe Removal es sair arm ig qu Hg a ag a a q V E q en a ae 22 Component Disassembly and Assembly SEIVICE Poo cita cada ia SO DECR DA E ti dan SAS GLORIA Cia DR M O 23 DiSassembIy TUI M 24 erm 29 Inspection PL d ad 29 ASCO EE 33 Installation Data ede ret peine oer eux epe nee eun MS Cn en ete Dupuis dus a nie nana EUN P MER RENE 40 Installation Checklisten een e dese e ed prende ce n pace aer aeneae ad en Renee equa ane ee au ada de nau ned eae phon ee date 41 General Information Introduction Page 4 Introduction General Information A turbocharger is a mechanical device which uses the engine s exhaust gases to force more air into the engine cylinders A turbocharger uses energy from the engine to help increase its overall efficiency Hot exhaust gas energy is used to turn a shaft and wheel 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
12. ctuator spigot Use a small screwdriver to care fully remove the hose clip 75 from the actuator spigot then remove the hose 81 from the actuator spigot Connect and secure the hose from the regulated air supply to the actuator spigot Caution Avoid touching the VG mechanism as finger injury may result from sudden movement of A the assembly when air is supplied Carefully apply pressure to the actuator from the regulated air supply Max 5bar 72 5psi and check for rod movement Caution If the actuator leaks air however little it A must be replaced Using a damaged actuator will lead to inferior performance of the turbocharger and therefore on the engine Also risking irreparable damage to both Optional Components Page 16 Component Identification Whilst the air is still on check the actuator for leaks Use soapy water and a small brush as shown small bubbles will appear if the actuator is leaking If the actuator is leaking it must be removed and replace with new Contact your local approved dealer for details Actuator Replacement Service Tools Page 17 Actuator Replacement Service Tools The following special tools are recommended to perform procedures in this manual The use of these tools is shown in the appropriate procedure These tools can be purchased from your local Authorised Repair Location Part No Tool Description
13. ed 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 Burnt valves and or pistons 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 Turbocharger damaged Find and correct cause of failure repair or replace turbocharger as necessary Failed diaphragm AEN Replace using correct actuator Service Kit Siezed valve Free valve replace complete turbine housing sub assembly Leaking hose Replace hose and clips Wastegate mechanism set incorrectl Contact approved agent for correct setting details Symbols Page 6 Symbols English 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 AA FOMOSBD gt gt gt amp Introduction 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 aREMOVAL or DISASSEM
14. guidas 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 AK FIOM sep gt E Assegure se de que as MARCAS DE BALANCEAMENTO do conjunto eixorotor estejam alinhadas Requer medi o EL TRICA amp ES 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 Component Identification Turbocharger Identification Page 11 Component Identification Turbocharger Identification dataplate is fitted to the compressor housing 8 The om M 35XXXXX information on this dataplate must be quoted for service and PN L HO1XXXX parts support HX55V Center Housing Rotating Assembly C H R A Components HX55V Component Identification Page 12 Components HX55V Item No Description Quantity 4 Bearing Housing 1 5 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 Piston Ring Seal Turbine 2 16 Piston Ring Seal Compressor 1 22 Inlet Baffle Retaining Ring 1 28 V band Clamp Turbine 1 29 V band Clamp Compressor 1 31 Oil Slinger 1 32 O Ring Seal Compressor 1 33 Oil Baffle 1 34 I
15. ineadas 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 Symbols Introduction Page 8 Symbole Deutsch In diesem Handbuch werden die folgenden Symbole verwendet die wesentliche Funktionen hervorheben Die Symbole haben folgende Bedeutung WARNUNG Wird die Warnung nicht beachtet dann besteht erh hte Unfall und Besch digungsgefahr VORSICHT Werden die Vorsichtsmassnahmen nicht beachtet dann besteht Unfall und Besch digungsgefahr AUSBAU bzw ZERLEGEN EINBAU bzw ZUSAMMENBAU INSPEKTION erforderlich Teil oder Baugruppe REINIGEN DIMENSION oder ZEITMESSUNG Teil oder Baugruppe LEN WERKZEUGGR SSE wird angegeben ANZUG auf vorgeschriebenes Drehmoment erforderlich AA FOMOSBD gt gt gt Sicherstellen daB die AUSWUCHTMARKEN an der Rotor Baugruppe richtig ausgerichtet sind Elektrische MESSUNG DURCHF HREN Weitere Informationen an anderer Stelle bzw in anderen Handb chern amp e Schutzkleidung mu immer getragen werden Introduction Symbols Page 9 Symboles Fran ais 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 A R G D EN ita amp AVER
16. intake manifold x Refer to engine manufacturer s manual and remove restriction Air leak in feed from air cleaner to compressor Replace seals gaskets or tighten fasteners as required Air leak in feed from compressor to intake manifold 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 e Remove restriction or replace damaged parts as required 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 eo Replace gasket or tighten fasteners as required Gas leak in ducting after turbine outlet e e Refer to engine manufacturer s manual and repair leak Restricted turbocharger oil drain line Remove restriction or replace damaged parts as required eje ee Restricted engine crankcase breather ele e Refer to engine 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 e o Refer to engine manufacturer s manual and replace or adjust faulty components as requir
17. king caused by overheating also check mounting flanges for signs of distortion Replace with new if any of the above are visible Bearing Housing 4 Inspect the bore for wear or score marks on both the bearing and piston ring area Also check all tapped holes are clean and free from dirt Replace with new if any damage is found Page 31 Inspection Component Disassembly and Assembly Page 32 Compressor Housing 8 Inspect the profile for damage due to possible contact with the rotor Also check the retaining ring groove area is free from deposits Replace with new if any damage is visible 7 Compressor Wheel 7 Inspect carefully for cracked bent or damaged blades but DO NOT ATTEMPT TO STRAIGHTEN BLADES Replace with new if any damage is found Component Disassembly and Assembly Minor Components Oil Slinger 31 Inspect and replace if the piston ring seal groove walls are scored or damaged Also check for signs of rubbing on the flat surfaces Groove Width mm in 1 664 MAX 0 0665 Oil Seal Plate 43 Inspect the seal bore replace if scored or damaged Assembly Caution Circlips 64 Premature failure will result if the circlips are fitted incorrectly Make sure that the circlips are always fitted with the bevelled edge facing the journal bearing Caution Rotor balance Before assembl
18. nlet Baffle 1 36 Thrust Collar 1 43 Oil Seal Plate 1 61 Locknut Compressor Wheel 1 62 V band Locknut 2 64 Ring Retaining Bearing Snap Ring 4 66 Insert Retaining Ring 1 73 Actuator Can 1 76 Link End Adjuster 1 83 Locknut Actuator 2 105 Connecter Male 1 112 Speed Probe 1 113 Adaptor Oil Inlet 1 114 O Ring Seal Oil Inlet 1 115 O Ring Seal Male Connector 1 116 Adaptor Oil Outlet 1 117 O Ring Seal Oil Outlet 1 118 Actuator Bracket 1 119 Bracket Bolts 2 120 Cap Head Screw 1 Component Identification Exploded View HX55V Exploded View HX55V Page 13 Oil Control Valve Page 14 Oil Control Valve The valve controls the pressure applied to the actuator in response to signals sent by the engines electronic control unit There are no service able parts inside If the engine diagnostics indicate a problem with the valve it must be relaced Contact your approved Dealer for parts and avialablilty Page 15 Actuator Checking and Replacement Caution Do not remove or adjust any components from the turbocharger unless instructed to do so A Place the turbocharger on a suitable work bench Before attempting to overhaul your VG turbocharger it is important to check the actuator for leaks To do so follow the procedure below Caution Wear safety glasses at all times during the disassembly process Checking the Actuator R So If the hose is still connected to the a
19. que value 17 Nm 150 in lbs Refit Actuator Refer to Page 17 Caution Make sure the scribe marks are aligned Install v band clamp 28 and tighten the v band lock nut Torque value 8 Nm 75 in lbs Secure the turbine housing and check the thrust clearance using a dial gauge Thrust Clearance mm in 0 038 MIN 0015 0 093 MAX 0037 Check the radial clearance using a dial gauge Radial Clearance mm in 0 394 MIN 0155 0 635 MAX 0250 Component Disassembly and Assembly Assembly Page 39 Caution the compressor wheel blades can be easily damaged when the compressor housing is installed Loosely fit the V band clamp Lubricate and install the O ring seal 41 if fitted Install compressor cover 8 Caution Make sure the scribe marks are aligned Install the V band clamp 29 and tighten the locknut 62 to the torque value Torque Value Locknut 62 8 5 Nm 75 in lbs Refit Speed Probe Refer to Page 22 Installation Data Component Disassembly and Assembly Page 40 Installation Data 1 Mount the turbocharger on the turbine inlet flange All other connections must be flexible and heavy pipework should be supported Always pre lube with clean engine oil Always position the bearing housing so that the oil drain is at the bottom and kept within 22 of the vertical centre line when installed on the engine Oil should be filtered below 15 20 microns The oil q
20. t connection is well made and will not leak in use Check the exhaust system is well supported and not causing excess loads on the turbocharger Fit any supports brackets back in position Check all hose pipe clamps studs nuts are correctly torqued Carefully assemble the turbocharger oil inlet pipe and check that the connection is clean well made and will not leak under pressure Do NOT use liquid gasket substances as any excess will enter the turbocharger oil system and obstruct oil flow damaging the turbocharger bearing system in use Crank the engine WITHOUT firing engine fuel pump stop out until engine oil flows out of the turbocharger drain flange Assemble the oil drain pipe and check that the connection is well made without obstruction Check that the engine fuel injection system is correctly regulated as per the manufacturers specifications Start the engine and leave ticking over at idle for approx 1 minute so that the oil supply system is fully operational including the new filter s Accelerate the engine and check that there are no leaks obstructions of the air oil gas under pressure Check that the hoses connections do not deform under normal operation Before switching off the engine leave it ticking over at idle for at least 1 minute to cool the turbine
21. turbine shaft and impeller nose If you intend to overhaul repair a core balanced turbocharger and do not have access to a core balancing machine we recommend that you make your own rotor co relation marks during disassembly see appropriate illustration in the disassembly section with an indelible ink pen so that these parts can be reassembled in the same relative positions Please refer to the balance data section of this manual for the balance limits to be used for either core balancing or rotor balancing It is important to note that operating a turbocharger with a Rotor or Core balance level greater than the published limits could cause turbocharger or engine failure If you are in any doubt regarding the balancing process please contact an approved Holset distributor for assistance Introduction Fault Finding Chart Page 5 Fault Finding Chart Cyclic Sound from the Turbocharger Oil Leak from Compressor Seal Poor Transient Response Engine Lacks Power Black Exhaust Smoke Blue Exhaust Smoke High Oil Consumption Turbocharger Noisy Oil Leak from Turbine Seal x D 5 ra o o ui Dirty air cleaner Clean or replace element according to manufacturer s recommendations Restricted compressor intake duct Remove restriction or replace damaged parts as required Restricted air duct from compressor to intake manifold Remove restriction or replace damaged parts as required Restricted
22. uality must be as specified by the engine manufacturer e g API CD MIL L 2104C Improvement in life can be obtained by using super high performance diesel SPHD oils particularly where extended oil drain periods are used Oil pressure must show at the turbocharger oil inlet within 3 4 seconds of engine firing to prevent damage to turbocharger bearing system from lack of lubrication The minimum oil pressure when the engine is on load must be 210 kPa 2 0 kgf cm 30 Ibf in and pressures up to 415 kPa 4 0 kgf cm 60 Ib in are satisfactory Under idling conditions the pressure should not fall below 70 kPa 0 7 kgf cm 10lbf in 6 The oil inlet pipe should be 9 5 mm 0 375 in bore minimum and the oil drain pipe should be no smaller than the turbocharger oil drain flange minimum The oil must drain downwards by gravity from the turbocharger into the engine under all operating conditions 7 Aircleaner pressure drop should not exceed 500 mm 20 in of water Avoid damp wet air conditions in filter as this can dramatically increase pressure drop on a temporary basis 8 The exhaust back pressure after the turbocharger should not exceed 500 mm 20 in of water Consult Holset where high restrictions are expected particularly when exhaust brakes are to be used Component Disassembly and Assembly Installation Checklist Page 41 Installation Checklist 1 2 3 13 14 15 16 7 18 19 20 21 Al
23. w to help in alignment during assembly Compressor housing 8 turbine housing 5 bearing housing 4 Ces Secure the turbine housing 5 in a vice Loosen and remove the compressor side V band locknut 62 y Caution The compressor wheel blades can be easily A damaged when the compressor housing is removed Gently remove the compressor cover 8 and if fitted Ge remove the O ring seal 41 4 SA Loosen and remove the turbine side V band locknut 62 Q Component Disassembly and Assembly Caution The turbine blades can be easily damaged when the turbine housing is removed Remove the C H R A from the turbine housing 19mm Locate the C H R A onto a 19mm socket clamped in the jaws of a vice or a suitable fixture Caution Always make sure the turbine wheel shaft and the compressor wheel have alignment marks before disassembly of the C H R A If no marks exist scribe the shaft and compressor wheel as shown before removing the compressor wheel locknut 13mm Remove the compressor wheel lock nut 61 Note Left hand thread Remove the compressor wheel 7 Disassembly Page 25 Disassembly Page 26 Component Disassembly and Assembly Remove the remaining C H R A from the socket and gently Ge slide the shaft and wheel 6 from the bearing housing 4
24. ways 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 intake and exhaust systems are clean and without obstruction ie free from oil gasket pieces dust dirt carbon or foreign objects Replace the oil and air filters using those only recommended by the equipment manufacturer Change the engine oil using the type specified by the engine manufacturer A minimum of CD oil is needed for the turbocharger diesel engine Check that the turbocharger oil inlet and drain connections are clean and free from obstruction and will not leak under pressure Mount the turbocharger on the exhaust flange and check that the turbine inlet gasket fits properly without obstructing the gas passages Rotate the turbocharger central bearing housing 4 so that the oil inlet and drain are in the vertical position Up to 22 Degrees from vertical is permitted Pour some clean engine oil into the turbocharger oil inlet hole and twist the turbocharger rotor assembly until clean oil starts to flow out of the oil drain flange Rotate the compressor housing 8 into the correct position and assemble the air intake and boost outlet connections Check that the connections are well made and do not have a possibility of leaking under pressure Assemble the exhaust system to the turbine housing outlet 5 Check that the gaske
25. y always make sure that both compressor wheel and assembly turbine wheel are individually balanced Then check balance the rotor assembly to ensure it is within the required limits Mark up each individual item to help ensure correct alignment during assembly Rotor Balance Limits Turbine End Compressor End gmm oz ins gmm oz ins 2 2gmm 4 4gmm 003 006 VA ee Inspection Page 33 Assembly Page 34 Component Disassembly and Assembly Ela Place the bearing housing 4 on a bench with the turbine end facing uppermost m Fit the inner circlip 64 with the bevelled edge facing SS upwards g Lubricate the journal bearing 11 and install into position Fit the outer circlip 64 with the bevelled edge facing the Ce bearing Turn the bearing housing over and repeat the process ER Install the two new piston ring seals 16 to the assembly Da turbine wheel 6 Component Disassembly and Assembly Caution Align the piston ring seals 16 so the gaps are positioned 180 apart Gently press down on the turbine wheel a slight rotation of the wheel will assist in properly locating the piston ring seals Lubricate the shaft using clean engine oil Support the assembly turbine wheel 6 in a suitable fixture EN Caution Align the balance mark on the thrust collar with that
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