Chile July 2008 Barry Haigh Technical Support WW Aftermarket

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 Introduction NOx g/kW.h Euro 2 Euro 3 Euro 4 Euro 5 US04* US07* US10* Japan 05 7.00 5.00 3.50 2.00 2.70 0.27 0.27 0.25 PM g/kW.h 0.250 0.100 0.020 0.020 0.130 0.013 0.013 0.015 2005 2002 2006 2004 2009 Australia Brazil China 2005 2008 2010 2014 EU 1996 2000 2005 2008 2004 2007 2010 India 2005 2010 2005 2010 2008 2010 Japan Korea Russia USA

*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

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 Centre Aftermarket India - Pune Customer Support Brazil - Sao Paulo Manufacturing Aftermarket India - Dewas Manufacturing Aftermarket

USA Charleston Leeds Ave Manufacturing

A Global Presence
USA Charleston Palmetto 236 people USA - Columbus 38 People UK - Huddersfield 1,042 People Holland - Amersfoort 11 People

USA - Memphis 7 People China Wuxi USA Charleston Leeds Ave 551 people 449 People

India - Pune 50 People Brazil - Sao Paulo 32 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 570K Capacity

Brazil - Sao Paulo 120k 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: Established: Location: Employees: Product Range: Cummins Turbo Technologies Ltd. In 1952 Headquartered in Huddersfield, UK 1,042 Light Duty, Mid Range, Heavy Duty, HHP: Holset HX20-25, HX30-35, HX40, HX50/55, HX60, HX80 Capacity: Activities: 450k Customer Account Teams, Manufacturing Technical Centre Aftermarket Other Facts: Cummins took ownership in 1973

India Operations
Name: Established: Location: Employees: Product Range: Capacity: Activities: Cummins Turbo Technologies Ltd. In 1994 as a JV with Tata Group of Companies Dewas and Pune, India Dewas: 221, Pune: 50 Light Duty, Mid Range: Holset HX20-25, HX30-35 400k 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: Established: Location: Cummins Turbo Technologies 1991 Leeds Ave & Palmetto, Charleston, South Carolina Columbus, Indiana Memphis, Tennessee Employees: Product Range: Capacity: Activities: Charleston: 787 Columbus: 38 Memphis: 7 Mid Range, Heavy Duty: Holset HE300 HE500 370k Palmetto, 580k Leeds Ave 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: Established: Location: Employees: Product Range: Capacity: Activities: Wuxi Cummins Turbo Technologies Co Ltd. 1996 Wuxi, China 449 Mid Range, Heavy Duty: Holset HX30-35, HX40, HX50-55 570k Customer Account Teams Technical Centre Manufacturing Aftermarket Other Facts: 45:55 JV between Wuxi Power and Cummins Turbo Technologies

Brazil Operations
Name: Established: Location: Employees: Product Range: Capacity: Activities: Cummins Turbo Technologies. 1987 Guarulhos (Sao Paulo), Brazil 32 Mid Range: Holset HX30-35, HX40 120k Customer Account Teams Manufacturing Aftermarket

Holland Operations
Name: Established: Location: Employees: Activities: Other Facts Cummins Turbo Technologies B.V. 1976 Amersfoort, The Netherlands 11 Aftermarket Distribution Centre Cummins Turbo Technologies acquired the business, formerly 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.

6cyl 6litre 120HP 344 kg

4cyl 4litre 80HP 247 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

Af

ter

co ole r

T et old l n I if n Ma

C 0 =4

T=

C ifold 0 a n 9 6 tM Comp = s T au h Turb Ex

180 C

T = 400C

T = 25C

Silencer
C 50 5 =

Air Filter T = 21C

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 1.6 Boost Press. (Bar) 1.4 1.2 1 0.8 0.6 0.4 0.2 0 0 500 1000 1500 Engine Speed (RPM) 2000 2500 3000
Sml t/hsg Med Lge

Wastegate valve open

t/hsg 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 leaking or stuck.
Check for 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 customers we need to work with and support them, to ensure it doesnt 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
Model Assy No Serial No Customer Pt No Attachments Customer Name: Customer Loc. Customer Ref Holset Location Date Inspected Application: ESN DIS: Life

DOF:

COMMENTS

CONCLUSIONS

SIGNED

DATE

Field Service
HOLSET TURBOCHARGER SUMMARY INSPECTION REPORT

SUMMARY INSPECTION REPORT NO 01

Model Assy No Serial No Customer Pt No Attachments HY55W 4038389 H040622080 504004854 Customer Name: Customer Loc. Customer Ref Holset Location Date Inspected Iveco Trucks Australia Application: ESN DIS: 29/10/04 Life Road Haul Engine No 36015 DOF: 27/12/05 440421 Km

23/02/06

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 INTAKE

Foreign Object Damage Compressor End

Cause : Rags,wrenches,nuts,screws,parts from the intake filter.
Damage to the blade tips

Disassembly & Inspection

Check the turbine intake for signs of solid objects. Note! Except in severe cases the turbine housing needs to be 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 discolouration and any 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 shutdown of the engine, poor quality lub. oil, infrequent service intervals, check for heavy carbon deposit in the bearing housing.

Hot Shutdown

Hot Shutdown

Oil Leakage

Blocked oil drain cavity

Oil Drain

Hot Shutdown - Overheating

Failure Diagnosis:
Hot Shutdown

340 Bearing Temperature oC 300 260 220 180 140 0 60 120 180 Time (secs) 240 300 360
Hot Shut Down from Peak Torque Temp Limit of CD Oil 1 min Idle 2 min Idle 3 min Idle

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 50 40 30 Holset Hovte

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 1 900 1100 1300 1500 1700 1900 2100

Holset Hovte

Engine Speed

Copy Turbos
Total Efficiency
60 50 40 30 900 1100 1300 1500 1700 1900 2100 2300 Holset Hosel

Holset Vs Copy 2
2.4 2.2 2 1.8 1.6 1.4 1.2 1 900 1100

Engine Speed

Compressor Outlet Pressure

Holset Hosel

1300

1500

1700

1900

2100

2300

Engine Speed

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 OEMs 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 Turbochargers consist of

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. Compressor Stage Bearing System

Turbocharger Basics
Turbine Housing Size: Effect on Boost Pressure
1.8 1.6

Boost Pressure (Bar)

1.4 1.2 1 0.8 0.6 0.4 0.2 0 0 500 1000 1500 2000 2500 3000

Watch out ! Excessive turbo speed

Lge t/hsg Med t/hsg Sml t/hsg

3500

Engine Speed (RPM)

VGT - Electronic Control 1 Turbine Housing Size: Effect on Strategy Boost Pressure
1.8 1.6

Wastegate Valve Open

Boost Pressure (Bar)

1.4 1.2 1 0.8 0.6 0.4 0.2 0 0 500 1000 1500 2000 2500 3000 3500 Lge t/hsg Med t/hsg Sml t/hsg

Engine Speed (RPM)

VGT - Electronic Control Strategy

Turbine Housing Size: Effect on Boost Pressure

2 1.8

Boost Pressure (Bar)

1.6 1.4 1.2 1 0.8 0.6 0.4 0.2 0 0 500 1000 1500 2000 2500 3000 3500 Lge t/hsg Med t/hsg Sml t/hsg VGT-typical

Engine Speed (RPM)

Holset VGTTM Performance benefit

Turbine Housing Size: Effect on Boost Pressure
2 1.8

Boost Pressure (Bar)

1.6 1.4 1.2 1 0.8 0.6 0.4 0.2 0 0 500 1000 1500 2000 2500 3000 3500 Lge t/hsg Med t/hsg Sml t/hsg VGT-typical VGT-open VGT-closed

Engine Speed (RPM)

Variable Geometry (VG) - Basics

By continuously varying the turbine housings 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
Nozzle ring fully closed Min. turbine volute exit area
Max. exhaust manifold pressure Max. shaft speed Max. turbo boost

One Piece Sliding Nozzle

Nozzle ring fully open
Max. turbine volute exit area
Min. exhaust manifold pressure Min. shaft speed Min. turbo boost

Nozzle ring in mid position

Reducing turbine volute exit area Increasing exhaust manifold pressure Increasing shaft speed Increasing turbo boost

VGT

VGT System - Pneumatic Actuation

Actuator development for VGTTM

1998 Pneumatic 2002 Electric Type 1

2007 Electric Type 2

2007 Type 2 SMART electric actuation

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

Actuator T Cable

Std USB cable Aspect

Interface Box

Holset SOFTWARE Interface Box

 We can see the number of hours run and life history

e.g what temperature and load and for how long

2007 Type 2 SMART electric actuation Diagnosis

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 VGT 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 pdfs:

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

x1 - Base Material Fatigue Properties x2 - Material selection and processing

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

x1 - Base Material Fatigue Properties x2 - Material selection and processing

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

x4 - Vehicle Usage and Application Duty Cycle

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 OF SIGNAL: ISX1_500HP_SUED.DAC

1.2E 5

T u r b oS p e e d( r p m )

0 9251.936
T im e (s e c )

9848.113

n Co d e n So ft

Any Questions?

Thank You