Catálogo de Turbos Cummins 2008 (Inglés) PDF

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 PM
g/kW.h g/kW.h Australia Brazil China EU India Japan Korea Russia USA
Euro 2 7.00 0.250 2005 1996 2005
Euro 3 5.00 0.100 2002 2004 2008 2000 2010 2005 2008
Euro 4 3.50 0.020 2006 2009 2010 2005 2010 2010
Euro 5 2.00 0.020 2014 2008
US04* 2.70 0.130 2004
US07* 0.27 0.013 2007
US10* 0.27 0.013 2010
Japan 05 0.25 0.015 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
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
TM
Turbocompound System
Serial 2 Stage
Product Plan
A Global Presence
USA – Charleston Palmetto UK - Huddersfield
Holland - Amersfoort
Manufacturing Headquarters
Aftermarket
USA - Columbus Technical Centre
Customer Support Manufacturing
Aftermarket
USA - Memphis
Aftermarket
China – Wuxi
USA – Charleston Leeds Ave Manufacturing
Manufacturing Technical Centre
Aftermarket
India - Pune
Customer Support
Brazil - Sao Paulo
Manufacturing
India - Dewas
Aftermarket
Manufacturing
Aftermarket
A Global Presence
Holland - Amersfoort
236 people 1,042 People
11 People
USA - Columbus
38 People
USA - Memphis
7 People
China – Wuxi
USA – Charleston Leeds Ave 449 People
551 people
India - Pune
50 People
Brazil - Sao Paulo
32 People
India - Dewas
221 People
A Global Presence with Increasing Capacity
370k Capacity 450k Capacity
China – Wuxi
USA – Charleston Leeds Ave 570K Capacity
580k 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: 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
Activities: Customer Account Teams,
Manufacturing
Technical Centre
Aftermarket
Other Facts: Cummins took ownership in 1973
India Operations
Name: Cummins Turbo Technologies Ltd.
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
Activities: 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 Technologies
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
Activities: 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 Technologies Co Ltd.
Established: 1996
Location: Wuxi, China
Employees: 449
Product Range: Mid Range, Heavy Duty:
Holset HX30-35, HX40, HX50-55
Capacity: 570k
Activities: 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: Mid Range:
Holset HX30-35, HX40
Capacity: 120k
Activities: Customer Account Teams
Manufacturing
Aftermarket
Holland Operations
Name: Cummins Turbo Technologies B.V.
Established: 1976
Location: Amersfoort, The Netherlands
Employees: 11
Activities: Aftermarket Distribution Centre
Other Facts 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

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 6cyl 6litre
or fit a turbocharger. 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

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.
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.
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
Wastegated
Bearing turbine housing
Housing
Turbine wheel
Compressor
Housing
Exhaust Outlet
Wastegate
actuator Turbine inlet
Typical Engine System
Af
ter
co
ole
r
0 °C
T =4
et old T=
nl 180
I nif °C
Ma C ifold
9 0° a n
= 6
s tM Comp
T au
h
Ex Turb
T = 400°C T = 25°C
Silencer Air Filter
C
°
5 50 T = 21°C
T =
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
1.6 valve open
1.4
Boost Press. (Bar)
1.2
Sml t/hsg
1
Med t/hsg
0.8 Lge t/hsg
0.6
0.4
0.2
0
0 500 1000 1500 2000 2500 3000
Engine Speed (RPM)
Wastegate Mechanism: Actuator-linkage-valve
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 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:
Assy No Customer Ref ESN
Serial No Holset Location DIS: DOF:
Customer Date Inspected Life
Pt No
Attachments
COMMENTS
CONCLUSIONS
SIGNED DATE
Field Service
HOLSET TURBOCHARGER SUMMARY INSPECTION REPORT
SUMMARY INSPECTION REPORT NO 01

Customer Name: Iveco Trucks Australia
Model HY55W Customer Loc. Application: Road Haul
Assy No 4038389 Customer Ref ESN Engine No 36015
Serial No H040622080 Holset Location DIS: 29/10/04 DOF: 27/12/05
Customer 504004854 Date Inspected 23/02/06 Life 440421 Km
Pt No
Attachments
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
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
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
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)
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.
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.
Remove the shaft & wheel,check for any

heat discolouration and any wear on the
shaft.
Remove the circlip
Remove the oil seal plate
Remove the O-ring seal
Check for damage to the O-ring seal

Remove the oil slinger from the oil
seal plate.
Check for wear or score marks in

the bore.
Remove the seal ring

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.
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
Hot Shut Down

from Peak Torque
300
Temp Limit of 1 min Idle
CD Oil
260 2 min Idle
220 3 min Idle
180
140
0 60 120 180 240 300 360
Time (secs)
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
Blade Root - Inclusion
Blade root - Linear/oxide blow

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

Engine Speed
1700 1900 2100
Compressor Outlet Pressure
2.4
2.2
2 Holset
1.8
1.6 Hovte
1.4
1.2
1
900 1100 1300 1500 1700 1900 2100
Engine Speed
Copy Turbos
Total Efficiency
60
50 Holset
40 Hosel
30
900 1100 1300 1500 1700 1900 2100 2300
Holset Vs Copy 2 Engine Speed
Compressor Outlet Pressure
2.4
2.2
2 Holset
1.8
1.6 Hosel
1.4
1.2
1
900 1100 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.
Genuine
Copy MAN Turbo
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.

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
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
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
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
Check that the oil inlet and drain flanges are clean and free from
obstruction.
Replace the gaskets

Replace the oil and filter using only OEM recommended parts and
specified oil grade & classification.
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.
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

Connect the oil drain line and then fill the turbocharger oil feed hole
with clean engine oil. Slowly rotate the rotor by hand.
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.

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 Compressor Stage
an exhaust-gas driven Bearing System
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 fuel-
rate. - i.e. at a fixed
fuelling rate, boost Area
pressure is also fixed.
Turbocharger Basics
Turbine Housing Size: Effect on Boost Pressure
1.8
Watch out !
1.6 Excessive
turbo speed
Boost Pressure (Bar)
1.4
1.2
1 Lge t/hsg
Med t/hsg
0.8
Sml t/hsg
0.6
0.4
0.2
0
0 500 1000 1500 2000 2500 3000 3500
Engine Speed (RPM)

VGT - Electronic
Turbine Housing Size:Control
Effect on Strategy 1
Boost Pressure
1.8 Wastegate
1.6 Valve Open
1.4
1.2
1 Lge t/hsg
Med t/hsg
0.8
Sml t/hsg
0.6
0.4
0.2
0
0 500 1000 1500 2000 2500 3000 3500
Engine Speed (RPM)

VGT - Electronic Control Strategy 1
2
1.8
1.6
1.4
1.2 Lge t/hsg
Med t/hsg
1
Sml t/hsg
0.8 VGT-typical
0.6
0.4
0.2
0
0 500 1000 1500 2000 2500 3000 3500
Engine Speed (RPM)

Holset VGTTM – Performance benefit
2
1.8
1.6
1.4 Lge t/hsg
1.2 Med t/hsg

Sml t/hsg
1
VGT-typical
0.8 VGT-open
0.6 VGT-closed
0.4
0.2
0
0 500 1000 1500 2000 2500 3000 3500
Engine Speed (RPM)

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
Fewer moving parts
Nozzle carried and
moved by 2 rods
Fewer potential wear
sites
Nozzle ring fully closed Nozzle ring in mid position Nozzle ring fully open
• Min. turbine volute exit area • Reducing turbine volute exit area • Max. turbine volute exit area
• Max. exhaust manifold pressure • Increasing exhaust manifold pressure • Min. exhaust manifold pressure
• Max. shaft speed • Increasing shaft speed • Min. shaft speed
• Max. turbo boost • Increasing turbo boost • 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
VGT System - Electronic 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
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
Aspect System: Interface Hardware & Software
Actuator
“T” Cable
Std USB cable

Aspect
Interface Box
Holset SOFTWARE
Interface Box
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:
®
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 ‘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
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
1.2E5
TurboSpeed(rpm)
0
9251.936 Time (sec) 9848.113
nCode nSoft
Any Questions?
Thank You

Catálogo de Turbos Cummins 2008 (Inglés) PDF

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Chile July 2008

 Cummins Turbo Technologies is an autonomous Business Unit

 The commercial turbocharger market has seen steady

 Growth is driven by increasingly stringent government

 Turbocharging technology is seen as a key tool in enabling

Euro 2 7.00 0.250 2005 1996 2005

Euro 4 3.50 0.020 2006 2009 2010 2005 2010 2010

Euro 5 2.00 0.020 2014 2008

US04* 2.70 0.130 2004

US07* 0.27 0.013 2007

US10* 0.27 0.013 2010

Japan 05 0.25 0.015 2005

 Cummins Turbo Technologies has developed advanced

 Can offer a portfolio of technology to meet our strategic

Brazil - Sao Paulo

We are continually developing our products to help customers to meet

All our sites are accredited with the internationally recognised

Cummins Turbo Technologies is working to reduce waste, reduce

Cummins Turbo Technologies aims to improve

Through ‘Community Action’ committees,

Consisting of a Holset HX52 and

Holset HX55 Turbocharger

Holset HE431V – Cursor 8

In turbochargers the exhaust gas energy which would normally

The advantages of a turbocharged engine are:

The Turbine End

The Compressor End

The Oil Supply

The waste exhaust gasses are

The turbine wheel is connected

As the turbine wheel increases in

The faster the wheels spin the,

As the air is sucked into the

This compresses the air and

This process causes the air to

Silencer Air Filter

Typically the wastegate valve

Check for air leakage

 high temp strength

 thermal fatigue resistance

other materials used on turbochargers :-

typically cast aluminum alloy - various grades

 elevated temp strength

 for special high pressure applications temperatures can exceed

the creep limits of aluminium in these applications Holset uses cast

 elevated temp strength

other materials used on turbochargers (usually on niche applications)

What temperatures do we see at the turbine

The purpose of analysing a ‘failed’ turbocharger is to determine the

We also need to determine who is responsible.

We need to prevent a reoccurrence - whether it is a Cummins Turbo

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

SUMMARY INSPECTION REPORT NO

HOLSET TURBOCHARGER SUMMARY INSPECTION REPORT

SUMMARY INSPECTION REPORT NO 01

How can we determine the root cause of the

Check for damage to the external surfaces,concentrating on

Check axial and radial clearances. Clearances can be found in the

Remove the core assy

Remove the turbine

Remove the shaft & wheel,check for any

Remove the circlip

Cummins Turbo Technologies is an autonomous Business Unit

The commercial turbocharger market has seen steady

Growth is driven by increasingly stringent government

Turbocharging technology is seen as a key tool in enabling

Cummins Turbo Technologies has developed advanced

Can offer a portfolio of technology to meet our strategic

high temp strength

thermal fatigue resistance

elevated temp strength

for special high pressure applications temperatures can exceed

elevated temp strength