Chile July 2008 Barry Haigh Technical Support WW Aftermarket
Agenda
Cummins Turbo Technologies Overview
Turbochargers
Failure Diagnosis
Counterfeit Turbochargers
Technology
Agenda
Cummins Turbo Technologies Overview
Turbochargers
Failure Diagnosis
Counterfeit Turbochargers
Technology
Introduction to Cummins Turbo Technologies
Cummins Turbo Technologies Overview
Cummins Turbo Technologies is an autonomous Business Unit of Cummins Inc
We are the leading designer and manufacturer of turbochargers for diesel and gas-derivative engines above 3 litres
We have over 2,500 employees globally
Headquartered in the UK with global manufacturing facilities in; Brazil, China, Europe, India and USA along with dedicated technical centres in UK and China
Global Customers:
Market Drivers:
The commercial turbocharger market has seen steady growth over the past few years. This is expected to continue into the next decade and beyond
Growth is driven by increasingly stringent government emissions legislation worldwide
Turbocharging technology is seen as a key tool in enabling engine manufacturers to meet these strict criteria
Emission Regulations: On-highway, heavy duty emissions legislation by country and date of introduction Date of Introduct ion NOx g/kW.h
PM g/kW.h
Euro 2
7.00
0.250
Euro 3
5.00
0.100
2002
Euro 4
3.50
0.020
2006
Euro 5
2.00
0.020
US04*
2.70
0.130
2004
US07*
0.27
0.013
2007
US10*
0.27
0.013
2010
Japan 05
0.25
0.015
Aust ralia
Brazil
China
EU
India
2005
1996
2005
2004
2008
2000
2010
2009
2010
2005
2014
2008
Japan
Korea
Russia
2005
2008
2010
2010
2005
*US limits converted from g/hp.hr to g/kW.h for comparison. US07 legislation requires that 50% of engines a manufacturer produces should meet the US10 NOx requirements
USA
Product Focus:
Cummins Turbo Technologies has developed advanced turbocharging technologies to enable engine manufactures to meet these strict emissions criteria
Can offer a portfolio of technology to meet our strategic customers’ target markets: Holset VGT with electric actuation Turbocompound System Serial 2 Stage
TM
Product Plan
A Global Presence USA – Charleston Palmetto Manufacturing USA - Columbus Customer Support
UK - Huddersfield Headquarters Technical Centre Manufacturing Aftermarket
Holland - Amersfoort Aftermarket
USA - Memphis Aftermarket China – Wuxi Manufacturing Technical Centr Aftermarket
USA – Charleston Leeds Ave Manufacturing
Brazil - Sao Paulo Manufacturing Aftermarket
India - Pune Customer Support India - Dewas Manufacturing Aftermarket
A Global Presence USA – Charleston Palmetto 236 people
UK - Huddersfield 1,042 People
Holland - Amersfoort 11 People
USA - Columbus 38 People
USA - Memphis 7 People China – Wuxi USA – Charleston Leeds Ave 551 people
Brazil - Sao Paulo 32 People
449 People
India - Pune 50 People India - Dewas 221 People
A Global Presence with Increasing Capacity USA – Charleston Palmetto 370k Capacity
UK - Huddersfield 450k Capacity
China – Wuxi USA – Charleston Leeds Ave 580k Capacity
Brazil - Sao Paulo 120k Capacity
570K Capacity
India - Dewas 400k Capacity
Aftermarket Support
Service/Spare Parts Focused on serving OEM global service networks
Specialised service, packaging & logistics
Dedicated facilities:
USA, China, Europe, India and Brazil
24 hour, 7 day per week coverage
Extended opening hours
Internet Ordering
Multi-lingual Staff
OEM Remanufacturing Service Independent channel of distributors
Local expertise, coverage of old, ex-OE production product, capable of specialised logistics service
Corporate & Social Responsibility
Our Environment Cummins Turbo Technologies is committed to providing a cleaner, healthier, safer environment in all aspects of our work We are continually developing our products to help customers to meet or exceed emissions and noise regulations whilst improving fuel economy All our sites are accredited with the internationally recognised ISO14001 environmental certification Cummins Turbo Technologies is working to reduce waste, reduce pollution and reduce energy consumption:
recycling paper and cardboard boxes, using scrap paper for notes, turning off lights and computer screens when not in use
Building a Brighter Future for our Local Communities Cummins Turbo Technologies aims to improve the quality of life in local communities through donations and by supporting the activities of our employees and business/community partnerships Through ‘Community Action’ committees, employees from all areas of the business develop new skills by taking on different challenges that benefit the local community
UK Operations Name:
Cummins Turbo Technologies Ltd.
Established:
In 1952
Location:
Headquartered in Huddersfield, UK
Employees:
1,042
Product Range:
Light Duty, Mid Range, Heavy Duty, HHP: Holset HX20-25, HX30-35, HX40, HX50/55, HX60, HX80
Capacity:
450k
Act ivi ties :
Customer Account Teams, Manufacturing Technical Centre Aftermarket
Other Facts:
Cummins took ownership in 1973
India Operations Name:
Cummins Turbo Technologies L td.
Established:
In 1994 as a JV with Tata Group of Companies
Location:
Dewas and Pune, India
Employees:
Dewas: 221, Pune: 50
Product Range:
Light Duty, Mid Range: Holset HX20-25, HX30-35
Capacity:
400k
Act ivi ties :
Dewas: Customer Account Teams, Manufacturing & Aftermarket Pune: Customer Account Teams, Global Support
Other Facts:
Became a Cummins wholly-owned foreign entity in April 2007
USA Operations Name:
Cummins Turbo Techno logi es
Established:
1991
Location:
Leeds Ave & Palmetto, Charleston, South Carolina Columbus, Indiana Memphis, Tennessee
Employees:
Charleston: 787 Columbus: 38 Memphis: 7
Product Range:
Mid Range, Heavy Duty: Holset HE300 – HE500
Capacity:
370k Palmetto, 580k Leeds Ave
Act ivi ties :
Charleston: Manufacturing Columbus: Customer Account Teams, Memphis: Aftermarket
Other Facts:
In July 2006, opened new purpose built second facility in Charleston; Palmetto
China Operations Name:
Wuxi Cummins Turbo Technolog ies Co Ltd.
Established:
1996
Location:
Wuxi, China
Employees:
449
Product Range:
Mid Range, Heavy Duty: Holset HX30-35, HX40, HX50-55
Capacity:
570k
Act ivi ties :
Customer Account Teams Technical Centre Manufacturing Aftermarket
Other Facts:
45:55 JV between Wuxi Power and Cummins Turbo Technologies
Brazil Operations Name:
Cummins Turbo Technologies.
Established:
1987
Location:
Guarulhos (Sao Paulo), Brazil
Employees:
32
Product Range: Range:
Mid Range: Holset HX30-35, HX40
Capacity:
120k
Act A ct i vi t ies :
Customer Account Teams Manufacturing Aftermarket
Holland Operations Name:
Cummins Turbo Techno Techno logi es B.V. B.V.
Established:
1976
Location:
Amersfoort, The Netherlands
Employees:
11
Act A ct i vi t ies :
Aftermarket Distribution Centre
Other Fact Facts s
Cummins Turbo Technologies acquired the business, business, formerly formerly Turbo Turbo Europa in 1993
Examples of Current Applications
Scania Euro IV Turbo Compound Engine
Consisting of a Holset HX52 and Holset HP72 power turbine
Volvo New HDEP Engine Platform – Euro IV
Holset HX55 Turbocharger
Ford F250 Pick-up
Holset HE221W
Chrysler Dodge Ram 07 – EPA 07
Holset HE351Ve
Iveco Cursor Engines for Stralis – Euro IV Holset HE431V – Cursor 8 Holset HE531V – Cursor 10 Holset HE551V – Cursor 13
Daewoo CNG City Bus – Euro III
Holset HX50G
Advantages of Turbochargers In turbochargers the exhaust gas energy which would normally be wasted is used to drive a turbine, which in turn drives a compressor to deliver compressed air to the engine. The advantages of a turbocharged engine are:
lower fuel consumption lower emissions better torque characteristics lower weight and smaller engine package lower engine noise
More Power Required Choice is either; Increase the size of engine or fit a turbocharger.
4cyl 4litre 80HP 247 kg
6cyl 6litre 120HP 344 kg
Turbocharged 4cyl 4litre 122HP 286 kg
Major Components of a Turbocharger Compressor Cover Compressor Wheel
Bearing Housing
Turbine Wheel
Turbine Housing
How a Turbocharger Works
The Turbine End
The Compressor End
The Oil Supply
How a Turbocharger Works The turbine housing is bolted to the exhaust manifold of the engine. The waste exhaust gasses are used to rotate the turbine wheel which is housed in the turbine casing.Turbine temperatures up to 760 deg C The turbine wheel is connected to a common shaft which in turn rotates a compressor wheel.
How a Turbocharger Works As more gas passed through the turbine housing, the faster the turbine wheel rotates. As the turbine wheel increases in speed, so does the compressor wheel. This creates a sucking process and pulls air into the compressor cover from the atmosphere (filtered). The faster the wheels spin the, the more air is sucked in.
How a Turbocharger Works
As the air is sucked into the compressor cover, it is forced through a diffuser area. This compresses the air and forces it into the engine This process causes the air to increase in temperature, up to 200 degrees C
Typical Turbocharger components Oil inlet
Impeller Wheel Bearing Housing
Wastegated turbine housing
Turbine wheel Compressor Housing
Wastegate actuator
Exhaust Outlet Turbine inlet
Typical Engine System
A f t er c o o l e r
4 0 = T e t l d I n l n i f o M a
T = 400
C
C
C i f o l d 9 0 M a n 6 t Comp T = a u s h Turb E x
T = 1 8 0
T = 25
C
C
Silencer
Air Filter
5 0 5 T =
C T = 21
C
Bearing System Journal Bearings
fully floating bearings - allows higher clearances, so higher oil flows for cooling
oil film thicknesses of 0.008 to 0.015 mm
leaded bronze
allow high degrees of imbalance
Thrust Bearing
taper land bearing
phosphor bronze or sintered iron
thrust loads of 100 - 2000 N (size dependent)
typical oil film thickness 0.008 - 0.015mm
Has to withstand high temperatures, hot shut down, soot loading in the oil, contaminants, oil additives, dry starts.
Turbocharger Basics – Wastegates A wastegate mechanism functions, by allowing some of the exhaust gas to bypass the turbine – thus limiting turbo speed & boost pressure. Typically the wastegate valve is only opened at high engine speeds & loads (used to prevent turbo speed or boost pressure from exceeding safe levels).
Wastegate Turbocharger Effect of Wastegate 1.8
Wastegate valve open
1.6 ) r a B ( . s s e r P t s o o B
1.4 1.2 Sml t/hsg
1 0.8 0.6 0.4 0.2 0 0
500
1000
1500 Engi ne Speed (RPM)
2000
2500
3000
Med
t/hsg
Lge
t/hsg
Wastegate Turbocharger Wastegate Mechanism: Actuator-linkage-valve
Wastegate Turbocharger
Wastegate Check Apply 3 bar (300 kPa) air pressure to ensure that the wastegate actuator is not l eaking or stuck.
Check fo r air leakage
Turbine Housing typically Spheroidal Graphite cast iron (ferritic) typically greensand mould, sand core profile machining to match the turbine blade shape normally the primary mounting point and load bearing interface for the whole turbo may include water cooling jackets in some applications operation can be up to 760 °C on some applications requirements
impact resistance (ductility) oxidation resistance high temp strength thermal fatigue resistance ease of machining
other materials used on turbochargers :
NiResist
Bearing Housing typically Grey (flake) cast iron (pearlitic) typically shell moulded cores to provide positional accuracy of bearing location and seals, shell mould or sand cast outer machined by a combination of milling, turning, drilling, tapping, honing complex geometries - particularly for water cooled housings and variable geometry turbos requirements
castability ease of machining rigidity thermal stability
Compressor Housing typically cast aluminum alloy - various grades gravity die cast or sand cast profile machining to match impeller blade shape operation can be up to 200 °C requirements
impact resistance (ductility) ease of machining
Impeller typically cast aluminium alloy cast by a variant of investment casting process, using rubber formers and plaster moulds started using this process in 1976 to allow the production of wheels with backsweep on the blades operation up to more than 200 °C possible requirements
fatigue strength elevated temp strength creep resistance corrosion resistance for special high pressure applications temperatures can exceed the creep limits of aluminium in these applications Holset uses cast titanium impellers
very sensitive to balance groove shape and to damage/defects
Shaft and Wheel high nickel superalloy investment cast blade profile machined operation up to 760 °C on some applications friction welded to forged steel shaft very sensitive to balance grooves, and defects or damage requirements
fatigue strength elevated temp strength creep resistance corrosion resistance
other materials used on turbochargers (usually on niche applications) :-titanium aluminide
ceramic (typically silicon nitride)
QUIZ
What temperatures do we see at the turbine end
A) 400 deg C B) 680 deg C C) 760 deg C D) 220 deg C
ANSWER C
TURBOCHARGER FAILURE ANALYSIS
Turbocharger Failure Analysis The purpose of analysing a ‘failed’ turbocharger is to determine the root cause of failure. We also need to determine who is responsible. We need to prevent a reoccurrence - whether it is a Cummins Turbo Technology problem or a customer / end user problem. If the problem is Cummins Turbo Technologies we need to ‘fix’ it. If the problem is the customer’s we need to work with and support them, to ensure it doesn’t happen again.
Customer Reported Faults Leak oil Broken Low power Noisy Gas leakage Seized High oil consumption Broken shaft Smoke
Failure Data Date in Service ( DIS ) Date of failure ( DOF ) Service Life ( Hours,Kms,Mls ) Application ( Truck,Bus,Off road,Genset ) Duty Cycle ( City bus,stand by genset,General freight ) Country in Service Reason for removal from vehicle. ( Need to be specific, not just leak oil or broken ) Turbocharger Serial Number ( Date of manufacture ) Assembly Number Customer Number is applicable Model
Field Service HOLSET TURBOCHARGER SUMMARY INSPECTION REPORT
SUMMARY INSPECTION REPORT NO Customer Name: Model
Customer Loc.
Application:
Ass y No
Cust omer Ref
ESN
Serial No
Holset Location
DIS:
Customer
Date Inspected
Lif e
DOF:
Pt No Att achmen ts
COMMENTS
CONCLUSIONS
SIGNED
DATE
Field Service HOLSET TURBOCHARGER SUMMARY INSPECTION REPORT
SUMMARY INSPECTION REPORT NO 01 Customer Name: Model
Iveco Trucks Australia
HY55W
Customer Loc.
Appli cation:
4038389
Custo mer Ref
ESN
Serial No
H040622080
Holset Loc atio n
Customer
504004854
Date Inspec ted
Ass y No
Pt No Attac hment s
Road Haul Engine No 36015
DIS: 29/10/04 23/02/06
Lif e
DOF: 27/12/05 440421 Km
Warranty Analysis
How can we determine the root cause of the problem?
Disassembly & Inspection
Check for damage to the external surfaces,concentrating on the flange areas where incorrect fitting of pipes or adaptors,may have caused damage.
Customer Responsibility
Disassembly & Inspection Check for compressor end foreign object damage by looking in the intake.
AIR INTA KE
Foreign Object Damage Compressor End Cause : Rags,wrenches,nuts,screws,parts from the intake filter. Damage Da mage to the th e bl blade ade ti tips ps
Disassembly & Inspection Check the turbine intake for signs of solid objects. Note! Except in severe severe cases the the turbine turbine housing housing needs to be removed removed (in order to inspect the blade tips).
TURBINE INLET
Foreign Body Turbine End
Disassembly & Inspection Check the overall appearance corresponds with the data supplied. (i.e. claim data is 10,000kms, but turbo appears to have been in use for much longer . Check axial and radial clearances. Clearances can be found in the CTT Service Data Sheet (current version can be downloaded from www.Holset.co.uk - Parts & Service section)
Disassembly & Inspection Remove the compressor housing Remove the core assy from the turbine housing
Remove the turbine housing and compressor cover and check for any wheel “touches” or “rubs” on the profile.
Disassembly & Inspection Remove the compressor wheel and check for signs of excessive oil on the backface.This could be due to oil carryover past the compressor seal ring. Check condition of the seal ring when removed. The most common cause of oil leakage, is a blocked air intake filter.
Disassembly & Inspection Remove the shaft & wheel,check for any heat discol discolourati ouration on and any any wear wear on the shaft.
Disassembly & Inspection Remove the circlip
Remove the oil seal plate
Remove the O-ring seal
Check for damage to the O-ring seal
Disassembly & Inspection Remove the oil slinger from the oil seal plate. Check for wear or score marks in the bore.
Remove the seal ring
Disassembly & Inspection
Remove the thrust bearing and thrust collar,check for blockage of the oil feed holes ( a common cause of thrust failure ). Check for heat discolouration and scoring marks of both the bearing and collar. If excessive radial clearance was found it is likely that the journal bearings will also be damaged.
Silicone Applied to Oil Inlet Gasket
Do not use silicone
Foreign Body Blocking the Oil Supply to the Thrust Bearing
Silicone blocking oil to the thrust bearing
Blocked Thrust Bearing Foreign object blocking the oil feed to the thrust system
Cause : Silicone from the oil feed pipe fitting. Cleanliness during service intervals,filters and oil.
Disassembly & Inspection Remove the compressor-end outer circlip and remove the journal bearing. Look for scoring marks on both the outside (OD) and inside (ID) diameters, this can be caused by oil contamination ( dirt ) in the oil.
Remove the turbine-end bearing. This bearing will normally be a much darker colour than the compressor bearing (due to higher operating temperature).
Oil Dirt Ingress
Cause : Service intervals overdue Cleanliness during service Poor quality oil Poor quality filters
Oil Dirt Ingress
Shaft wear from oil dirt ingress
Oil Contamination New bearing Contaminated bearing
Check the colour of the bearing, a natural darkening with age is acceptable. A duller,powdery surface is an indication of engine coolant in the oil - the same appearance will normally also be found on the thrust bearing.
Oil Delay Bronze particles on the shaft
Causes :Restricted oil feed pipes. Low oil level in the sump Blocked oil filter Long periods on Non – use Lack of priming
Oil Starvation
Cause : Oil pump failure Broken oil feed pipe No oil in engine.
Hot Shutdown - Overheating
Cause: Hot shut down of the engine, poo r quality lub. oil, infr equent service intervals, check for heavy carbon deposit in the bearing housin g.
Hot Shutdown
Hot Shutdown
Oil Leakage
Blocked oil drain cavity
Oil Drain
Hot Shutdown - Overheating
Failure Diagnosis: Hot Shutdown
C o e r u t a r e p m e T g n i r a e B
340 300 260
Hot Shut Down from Peak Torque 1 min Idle
Temp Limit of CD Oil
2 min Idle
220
3 min Idle
180 140 0
60
120 180 Time (secs)
240
300
360
Excessive Engine Temperatures Delamination of the dividing wall and erosion of the gas entry.
Turbine housing cracked.
Cause : Incorrect fuel/air ratio, caused by blocked air intake filter, or overfuelling, etc.
Oil Leakage External - Common Causes : Loose / Damaged oil inlet and oil drain fittings. If fitting a new gasket and tightening the fittings does not stop the leak,then look for a damaged oil line or leaking centre housing. Internal Compressor & Turbine - Common Causes : Restriction in the turbo oil drain will ‘force’ oil past the split ring seals at both the turbine and compressor ends. Oil leakage at both ends simultaneously is a good indicator that this may be the problem Engine blow by pressure - which can be due to the engine crankcase vent being blocked by damage,plugging or icing.
Oil Leakage
Restriction
Oil Leakage - Compressor
An inlet ‘depression’(vacuum) greater than 25 in water will ‘pull’ oil past the compressor end split ring seal. THIS WILL NOT DAMAGE THE TURBO UNLESS THE THRUST BEARING FAILS. Typical cause is a blocked air intake filter or collapsed intake pipe.
Compressor End Oil Leakage
Compressor End Oil Leakage
Oil Leakage
Holset - Responsibility Failure due to manufacturing quality defect.
Failure due to design defect.
Material Defects (casting porosity, inclusions, oxide blows, etc ).
Turbine High Cycle Fatigue (HCF) - Examples Occurs when blades are run for extended periods at a sub-harmonic of the blade natural resonance frequency Casting defects can bring blade resonance into running range, even though designed to be outside Exact failure location varies, dependant on vibration mode and wheel design
Turbine Low Cycle Fatigue (LCF) - Examples Typically due to casting defects but instances of fatigue initiating in, for example, out-of-specification balance cuts have been seen Defect presence raises local stresses and initiates fatigue Defects have variety of appearances and sizes
Impeller LCF - Defects Duty cycle Defect presence raises local stresses and initiates fatigue Defects have variety of sizes and appearances There are three common failure locations - back face, suction side exducer blade root and the bore (highest stresses) Back Face
Impeller LCF - Defects Blade Root - Inclusion
Blade root - Linear/oxide blow
Impeller LCF - Defects Bore
Bore inclusion Bore cavity
Cause of failure could also be due to overspeed
Balance - Related Failures
Balance failures due to a manufacturing problem (hence Holset Responsibility) usually occur in very early life. (i.e. most within 500 km). If a balance failure occurs in late life - it is normally caused by wheel foreign-object damage, turbo overspeed or tampering) Balance failure causes: Parts misaligned Rotor parts replaced without check-balancing Incorrect parts used.
Noise Causes of “noisy turbo” complaints High level of rotor imbalance
(if very early life - i.e. less than 1k km, most likely a Holset issue - if later in life, look for foreign-object damage or bearing damage which caused a wheel rub, etc).
Turbocharger bearing housing joints - loose screws, V clamps. (A/Mkt turbos fitted,OE orientation factory set ).
Check for signs of leakage/damaged jointing surfaces.
Air or exhaust leaks on external turbo flanges
Look for soot on the turbine inlet and exhaust flanges, check if fasteners are loose , or surfaces damaged.
Non-turbocharger issues (water pump, fan belt, etc, etc).
Closed Crankcase Ventilation Future legislation may prohibit all uncontrolled engine emissions, including crankcase blow-by gases. Some applications already require closed crankcase ventilation systems. CCV systems filter the crankcase emissions from
engine piston rings
valve stem leakage
turbocharger seal leakage
air compressor leakage
These are generally routed to the turbocharger compressor inlet The long term effects of blow-by gases on turbocharger efficiency are a concern. Large efficiency losses can arise even with very low carry over rates.
Closed crankcase ventilation system Filter system
Crankcase blowby gases Engine
Intercooler
Compressor inlet
Exhaust
Compressor fouling due to CCV system
• Oil deposit build up can be significant over a period of time
Fitting a Replacement Turbocharger Each HOLSET turbocharger is designed to match a specific engine specification (power, speed, charge cooling etc). The turbocharger dataplate information includes: •
Assy Number
•
Serial Number
•
Customer Number
It is important that the Assy Number shown is the correct number for that engine, per the engine manufacturers specifications. DO NOT REMOVE THE DATA PLATE
Copy Turbos
Copy Turbos
Introduction: Copies are flooding the market from China &Brazil. Many varieties Hosel, Hovte, Hobest and Tian Di They look good (to the untrained eye) Cheap: Approx. 1/2 price of original Holset Turbo
Copy Turbos
Back to Back Engine tests: Three copies tested Results follow findings of wastegate settings Low boost and air flow Generally lower total efficiency, by 2-8% Results to be analysed and interpreted for a customers view point i.e. loss of power, fuel consumption, emissions
Copy Turbos Total Efficiency 70 60 Holset
50
Hovte 40 30
Holset Vs Copy 1
900
1100
1300
1500
1700
1900
2100
Engine Speed
Compressor Outlet Pressure 2.4 2.2 2 1.8 1.6 1.4 1.2 1
Holset Hovte
900
1100
1300
1500
1700
Engine Speed
1900
2100
Copy Turbos Total Efficiency 60 50
Holset
40
Hosel
30 900
1100
1300
Holset Vs Copy 2
1500
1700
1900
2100
2300
Engine Spe ed
Compressor Outlet Pressure 2.4 2.2 2 1.8 1.6 1.4 1.2 1
Holset Hosel
900
1100
1300
1500
1700
Engine Speed
1900
2100
2300
Copy Turbos
Containment Tests None of the copy turbos passed containment test None reached the required containment speed of 147k rpm Burst speeds: Copy1 = 142k rpm Copy2 = 136k rpm Copy3 = 134k rpm Copy4 = 144k rpm
Copy Turbos
Compressor Containment Tests Hobest: FAILED
Copy Turbos Compressor Containment Tests Copy1 : FAILED
Copy Turbos
Compressor Containment Tests Tian Di: FAILED
Copy Turbos
Compressor Containment Tests Hovte: FAILED!
Copy Turbos
Compressor Containment tests This is what they should look like:
These are Holset Turbos that have past the containment test
MAN – Turbocharger Turkey Genuine CTT bar code which is placed over the data plate. This turbo H050635285 was a genuine turbo sold to MAN parts.
Bar code label covered the nameplate. This is a copy nameplate as all turbos manufactured in Wuxi Holset have a ‘W’ not a ‘H’ in front of the Serial Number.
Copy MAN Turbo HOLSET genuine turbo
Copy turbo – See nut, machining and the shape of the struts.
Copy MAN Turbo
Genuine
Copy Turbo – No washers on the screws,machining,flat on the wastegate rod. PS – ignore the shape of the bracket.
Genuine
Copy MAN Turbo Holset
Copy turbo – Hose clip and hole in the capsule
Impeller Locknut
Copy
Genuine
Oil Seal Plate Retaining Ring
Copy
Genuine Difference Machined
Compressor Housing Retaining Ring
Genuine
Copy
Machined
Difference
Turbine Housing Screws Genuine Copy
Copy Turbo HT3B 3522867
General Observations : No Holset casting numbers marks on any components. Impeller wheel had a casting identification ‘R’
( Ross Foundry )
The turbine housing and bearing housing castings looked porous. Compressor Front Wheel clearance .023” ( Within Holset tolerance ) The turbine wheel has a recess machine on the backface. ( Suspect this could weaken the wheel ) Journal bearing have a groove in the bore. General quality looks poor from other copy turbos seen. Recommendations : Containment test.
Possible containment issue due to lack of material
Damaged oil baffle
‘R’ casting ident Recess machined on backface
Grooves in the bore of the Journal bearing
Copy Turbo HC5A 3523850
General Observations : No Holset casting numbers marks on any components. Impeller wheel had a casting identification ‘J’ General quality looks good from other copy turbos seen. Recommendations : Containment test.
‘J ‘ casting ident
VIDEO
Preventative Maintenance
Maintenance schedules recommended by the OEM should be strictly adhered to.
DO NOT USE inferior oil and air filters.
Use oil recommended by the OEM.
Preventative Maintenance Air filters should be changed at the OEM’s recommended intervals or earlier when operating in severe conditions. WARNING : Running the engine with a partially blocked air intake filter will increase fuel consumption and could also lead to turbocharger oil leakage. High exhaust back pressure can lead to temperature related problems with the turbocharger specifically bearings and seals. It is recommended that all clamps,hose clips,nuts & screws are checked at the routine service intervals. The correct torques can be found in the HOLSET Service Repair Manual
Preventative Maintenance REMEMBER :
Cold start - Requires good start up procedure.
The longer the engine is allowed to cool down the less damage is done to the turbo
Fitting a Replacement Turbocharger
It is important to understand why the original turbocharger requires replacing.
Determine the cause of any engine or vehicle failure and rectify,before fitting a replacement turbocharger
Fitting a Replacement Turbocharger Each HOLSET turbocharger is designed to match a specific engine specification (power, speed, charge cooling etc). The turbocharger dataplate information includes: •
Assy Number
•
Serial Number
•
Customer Number
It is important that the Assy Number shown is the correct number for that engine, per the engine manufacturers specifications. DO NOT REMOVE THE DATA PLATE
Fitting a Replacement Turbocharger It is important that the engine intake / exhaust systems are checked for debris. It is recommended that the air intake filter is changed using only OEM genuine parts
Fitting a Replacement Turbocharger Check that the oil inlet and drain flanges are clean and free from obstruction. Replace the gaskets
Fitting a Replacement Turbocharger Replace the oil and filter using only OEM recommended parts and specified oil grade & classification.
Fitting a Replacement Turbocharger Ensure the engine manifold mounting flange and studs are in good condition and are not warped or bent. Check for any cracks. Check the oil intake line is free from dirt or carbon, if in any doubt replace the line and fittings with new ones. Mount the turbocharger on the manifold and check that the turbine inlet gaskets fits correctly.
Fitting a Replacement Turbocharger The orientation of the bearing housing or compressor housing may require changing, to align correctly with the air, oil and water connections. Make sure all fasteners are tightened to the specified torque when the orientation is set. Take care not to damage any ‘O’ rings when changing the orientation of the compressor housing as this could cause air leakage. See Holset Service Manual for the recommended torque settings
Fitting a Replacement Turbocharger
Connect the oil drain line and then fill the turbocharger oil feed hole with clean engine oil. Slowly rotate the rotor by hand.
Fitting a Replacement Turbocharger
Connect the oil inlet line and the remaining external fittings to the turbocharger.
Pull out the fuel stop and crank over the engine using the starter motor, until normal operating engine oil pressure is developed.
Check for any oil leaks from the connections.
Fitting a Replacement Turbocharger Start the engine and idle,checking that all air,gas and oil connections are tight and free from leakage. Tighten any fastenings as required. Use soapy water to help detect air and gas leaks.
Technology
®
Holset VGT Overview
Turbocharger Basics – Fixed Geometry
Compressor Stage Turbochargers consist of Bearing System an exhaust-gas driven turbine connected to and driving a radial compressor, providing a Turbine Stage boosted air supply to the engine. At a given engine speed, turbo speed (hence boost pressure) can be changed ONLY by changing fuelrate. - i.e. at a fixed Area fuelling rate, boost pressure is also fixed.
Turbocharger Basics Tu rbin e Hous in g Size: Effect on Boo st Pressu re
Watch out ! Excessive turbo speed
1.8 1.6 ) r 1.4 a B (
1.2
e r u 1 s s e r 0.8 P t s 0.6 o o B 0.4
Lge t/hsg Med t/hsg Sml t/hsg
0.2 0 0
500
1000
1500
2000
Eng ine Speed (RPM)
2500
3000
3500
Turbi n e Hou sin g Size: Effect on Boost Pressu re
Wastegate Valve Open
1.8 1.6 ) r 1.4 a B ( 1.2 e r u 1 s s e r 0.8 P t s 0.6 o o B 0.4
Lge t/hsg Med t/hsg Sml t/hsg
0.2 0 0
500
1000
1500
2000
Eng ine Speed (RPM)
2500
3000
3500
Tu rbi n e Hou si n g Size: Effect on Boos t Pressu re 2 1.8 ) 1.6 r a B ( 1.4
e r 1.2 u s s 1 e r P 0.8 t s o 0.6 o B 0.4
Lge t/hsg Med t/hsg Sml t/hsg VGT-typical
0.2 0 0
500
1000
1500
2000
Eng ine Speed (RPM)
2500
3000
3500
Holset VGTTM – Performance benefit Tu rbi n e Hou si n g Size: Effect on Boos t Pressu re 2 1.8 ) 1.6 r a B ( 1.4
Lge t/hsg
e r 1.2 u s s 1 e r P 0.8 t s o 0.6 o B 0.4
Med t/hsg Sml t/hsg VGT-typical VGT-open VGT-closed
0.2 0 0
500
1000
1500
2000
Eng ine Speed (RPM)
2500
3000
3500
Variable Geometry (VG) - Basics
By continuously varying the turbine housing’s critical area the exhaust gas can now vary the speed of the turbo, boost pressure and exhaust manifold pressure – independent of engine speed and load.
Various ways of achieving Variable Geometry (VG)
Variable Geometry (VG) Swing Vane – non Holset
Turbine wheel is surrounded by a ring of nozzle guide vanes.
Flow area varied by changing the angle of these vanes in unison.
Holset VGTTM
-
One Piece Sliding Nozzle Sliding Nozzle
Holset VGTTM
-
One Piece Sliding Nozzle Fewer moving parts Nozzle carried and moved by 2 rods Fewer potential wear sites
Holset VGTTM
-
One Piece Sliding Nozzle
Nozzle ring f ully closed
Nozzle ring in mid p osition
Nozzle ring fully open
• Min. turbi ne volute exit area
• • • •
• Max. turbine volute exit area
• Max. exhaust m anifold pressure • Max. shaft s peed • Max. turbo boost
Reducing turbine vol ute exit area Increasing exhaust manifold p ressure Increasing shaft sp eed Increasing turbo boos t
• Min. exhaust manifold pressure • Min. shaft sp eed • Min. turbo boost
VGT
a
VGT System - Pneumatic Actuation
Actuator development for VGTTM 1998 Pneumatic 2002 Electric Type 1
2007 Electric Type 2
2007 Type 2 SMART electric actuation
1
2007 Type 2 SMART electric actuation
VGT System - Electronic Actuation
2007 Type 2 SMART electric actuation No external moving parts – direct fit on bearing housing
On-board microprocessor – relieves load on engine ECU
Position request from engine ECU via CAN network
Sends status message back to engine ECU:
Actual position v target position
Internal temperature
Motor effort
2007 Type 2 SMART electric actuation
An on-board thermistor monitors temperature. Current limiting is applied if the internal temperature exceeds a safe limit.
Motor-effort is monitored, and a de-rate applied under limiting conditions.
Has integral event log: 250 error codes – retrievable through OBD connection – or via Holset hardware and software
2007 Type 2 SMART electric actuation Aspect System: Interface Hardware & Software
Ac tuat or “ T” Cab le
Std USB cable
Aspect Interface Box
Holset SOFTWARE Interface Box
2007 Type 2 SMART electric actuation Diagnosis
We can see the number of hours run and life history
e.g what temperature and load – and for how long
Turbocharger Basics – Variable Geometry Variable Geometry benefits include:
Modulate EGR flow-rate
Reduce emissions
Higher engine power density
Increase engine ‘usable’ speed range
Increase low speed torque
Improve transient response & ‘driveability’
Enhance engine braking
Technical Literature on Website:
Technical Literature on Website:
Technical Literature on Website:
Technical Literature on Website:
Holset Parts Supply
Current Supply Pneumatic VGT
Currently supply – New and Reman turbos to OES In addition to complete VGT we offer the following parts to Distributors Parts : Repair kit, Actuator kit, Gasket kit, Speed Sensor kit, Outer Seal Ring, Shroud plate, Retaining Ring and V band.
Service Parts Support for the Holset VGT Service Actuator Kit:
Actuator
Gasket
Patch-treated capscrews (4)
Sector-gear alignment pin
Tube of Synthetic Grease
Tie wrap (4)
Instruction sheet.
Actuator Fitting kit:
As above, but without actuator
Service Parts Support for the Holset VGT Turbocharger Speed-Sensor Kit:
Sensor
O-ring
Capscrew
Software package
Technical Literature for Type 2 Actuator The following documents are all available as ‘pdf’s’:
Holset Type 2 Actuator Kit - Instruction Sheet.
Holset Type 2 Actuator Service Manual.
Holset HE500Ve Turbocharger Service Manual
Holset HE400Ve Turbocharger Service Manual
www.holsetaftermarket.com
Technical Literature for Type 2 Actuator
Technical Literature for Type 2 Actuator
Machined From Solid Impeller MFS Overview
Base materials properties improved in MFS impellers due to increased alloy content and fine grain structure from forging process
Inherently low level of oxides in wrought alloy used to make MFS impellers
Fine grain structure in MFS leads to improved fatigue life
MFS Impeller
Fine grain structure in MFS leads to improved fatigue life
Cast microstructure
Forged microstructure
Defect (casting process) related failures not experienced in MFS impellers
Oxide casting defect
Fatigue damage created locally on a component due to the changes in stress/strain produced during the normal operation of the turbocharger. These changes in stress/strain are directly related to the changes in turbocharger speed in any typical duty cycle. MFS material has improved fatigue resistance over cast material DISPLAY
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ISX1_500HP_SUED.DAC
1.2E5
) m p r ( d e e p S o b r u T
0 9251.936
nCode
nSoft
Time (sec)
9848.113