HE201W

8/18/2019 HE201W

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1

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

http://www.holset.co.uk/files/4_1-nearest%20distributor.php

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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


http://www.holset.co.uk/partsservice/service/HE-service-data-sheet.pdf



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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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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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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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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.

Component IdentificationHE201W/211W/221W Service Repair Manual


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Component Identification

Installation OptionsType A

Type B

Type C



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Installation OptionsType D

Type E

Type F

Component IdentificationHE201W/211W/221W Service Repair Manual


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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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Exploded View - Optional Parts

4

80

67

5

74 74

76

74

136

81


NOTICEExploded views represent a generic build standard. Parts may be added or subtracted in specific

applications.



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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 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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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.


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.


On Engine Checks






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WARNING


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


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


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.

Component Testing and ReplacementHE201W/211W/221W Service Repair Manual


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WARNING


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 .


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 .


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.


Turbine and Compressor Housings

WARNING


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.


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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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


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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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


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.


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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WARNING


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


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.


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


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.


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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4:15

Check for free rotation of rotor assembly.

CAUTION

To refit wastegate actuator refer to Actuator

Reassembly.

Component Testing and ReplacementHE201W/211W/221W Service Repair Manual


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4:16

WARNING


WARNING


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).


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


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).


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


Place turbocharger on suitable workbench. Use pointnose pliers to remove actuator clip.


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


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.


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


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.


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


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.


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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WARNING


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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WARNING


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.


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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WARNING


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.


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


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.


WARNING


Fit new splt pin, end link.







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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


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).


Adjusting nut

Gimbal

3mm Allen Key

Loosen and remove actuator clamp.


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4:27


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


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


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).


WARNING


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.


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


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


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.


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


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 .


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


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.


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


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.


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


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.


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


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.


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


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.


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.


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.


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


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.


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.


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.


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


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.


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


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.


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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5:15

WARNING


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.


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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5:16

WARNING


Use suitable circlip pliers to install retaining ring, insert(66).

CAUTION

Retaining ring must be fitted with chamfered faceupwards away from oil seal plate.


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.


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


Check compressor end radial movement using dialgauge. Ensure clearance lies within MIN/MAX TIR

(Total Indicator Reading) values shown onService Data Sheet .


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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5:19

WARNING


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.


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


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.



8/18/2019 HE201W


C i T b T h l i Ltd

Holset HE201W/211W/221WService Repair Manual


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HE201W

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