Holset Turbochargers OEM Service & Repair Manual

Holset WH2D Service Repair Manual Copyright 2007, Cummins Turbo Technologies Ltd. All rights reserved. VGT, Command Valve and Super MWE are trade marks of Cummins Turbo Technologies Ltd. Holset and the Holset Logo are registered trade marks of Cummins Turbo Technologies Ltd. Cummins and the Cummins logo are registered trade marks of Cummins Inc.

WH2D Service Repair Manual Foreword Foreword This publication was written to assist with turbocharger installation, maintenance and overhaul. It is not a warranty of any kind expressed or implied. The specifications and procedures in this manual are based on information in effect at the time of publication. Holset Service reserves the right to make any changes at any time without obligation. If differences are found between your turbocharger and the information in this manual, contact your local Holset approved agent. The latest technology and the highest quality standards are used in the manufacture of Holset Turbochargers. When replacement parts are needed, we recommend using only genuine Holset parts.

WH2D Service Repair Manual Table of Contents Table of Contents 1: Introduction About the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:1 How to Use the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:1 How to Order Holset Original Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:1 Description and Operation of Turbocharger ............................. 1:2 General Information ............................................. 1:2 Introduction to Turbocharger Matching ............................... 1:2 Notes, Cautions and Warnings ..................................... 1:3 Installation Data..................................................... 1:4 Installation Checklist ................................................ 1:5 Symbols ........................................................... 1:6 2: Component Identification Turbocharger Identification ........................................... 2:1 Dataplate and CHRA (Core) of Turbocharger .......................... 2:1 Exploded Views ..................................................... 2:2 Component List ..................................................... 2:3 Purchasable Service Tools............................................ 2:5 3: Troubleshooting and Diagnosis Fault Finding Chart .................................................. 3:1 4: Component Testing and Replacement Service Tools ....................................................... 4:1 On Engine Checks .................................................. 4:2 Bearing Clearance ................................................... 4:5 Turbine and Compressor Housings .................................... 4:6 Cleaning of Housings ............................................... 4:13 Wastegate Actuator Checks .......................................... 4:15 Actuator Removal................................................... 4:17 Wastegate Mechanism Check ......................................... 4:18 Actuator Replacement ............................................... 4:20 5: Turbocharger Service and Overhaul Service Tools ....................................................... 5:1 Disassembly ....................................................... 5:2 Component Cleaning ................................................ 5:7 Inspection and Testing ............................................... 5:9 Reassembly ....................................................... 5:13 6: Service Data Sheets H Range Service Data Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6:1

WH2D Service Repair Manual Introduction 1:1 About the Manual The procedures in this manual were developed to instruct in the correct overhaul of the designated Holset turbocharger range for optimum performance and minimum maintenance operation. How to Use the Manual The manual is split into sections designed to provide service information in a logical sequence. The manual contains links to help the user navigate between relevant sections. Users who are unfamilier with navigating in PDF documents are refered to Navigating in PDF documents in the Adobe® Acrobat® Reader™ help file. Contents is an interactive page with links to all the sections. It can be accessed from any page in the manual by clicking this icon. Section 1 defines the layout of the manual, introduces the reader to the operation of the turbocharger and presents important installation guidelines. Sections 2, 3 and 4 concentrate on Turbocharger Component Identification, Troubleshooting and Diagnosis, Component Testing and Replacement. Section 5 identifies the Service and Overhaul procedures to be followed in the unlikley event of a major turbocharger malfunction. Section 6 quantifies build data to ensure the turbocharger will continue to operate to Holset Service standard on completion of overhaul. Manual sections 1 to 5 where applicable, appear as a self extracting compressed file which is organised according to the steps needed to most easily and correctly maintain the operation of the turbocharger. Users are required to download this file to hard disk. Section 6 has its own file identity and resides at www.holset.co.uk. so that Holset can update the Service Data as changes occur. The links between manual and service data are active only when the user is connected to the Internet. Chapter 6 has an expiry date to encourage users to discard outdated saved or printed versions and always access the latest information available at www.holset.co.uk. When using the manual on-line this icon will link to Holset’s website to help find your nearest agent for advice and how to order Holset original parts. How to Order Holset Original Parts To make sure of optimum performance, certain items must be discarded during disassembly and replaced with new for re-assembly. These items are indicated in the Service and Overhaul section with the use of a * symbol. All items showing a * are available in a basic overhaul kit. To get the correct parts for your turbocharger, refer to the ‘component identification’ section of this manual to help you find the following information: 1) Refer to the exploded view and component list to define the major components to be replaced. 2) Refer to the turbocharger’s dataplate which will be found on the compressor housing or wastegate actuator to define the identifying information about your turbocharger build standard. 3) Contact your local Holset agent with componant identification nos. and dataplate assembly no., serial no. and turbocharger type. 4) With this information, your local agent can provide you with the optimum kit of parts for re-assembling your turbocharger for continued long life operation.

WH2D Service Repair Manual Introduction Description and Operation of Turbocharger 1:2 General Information A turbocharger is a mechanical device which uses the engine’s exhaust gases to force more air into the engine cylinders. Hot exhaust gas energy is used to turn a turbine wheel and shaft. At the other end of the shaft is the compressor impeller (or compressor wheel), which draws in air and forces it into the engine cylinders. Supplying increased air mass flow to the engine provides improved engine performance, lower exhaust smoke density, improved operating economy and altitude compensation. The turbocharger has proven to be one of the most beneficial devices for improving engine performance. It performs its job very well, as long as it is properly cared for. Introduction to Wastegate Turbochargers The need for wastegated turbochargers A standard turbocharger can be perfectly matched to only one particular engine condition, eg maximum torque speed or maximum load speed. At this engine speed, the turbocharger supplies the optimum mass of air to give the required air/fuel ratio. At other speeds the air/fuel ratio cannot be held at the optimum hence fuel consumption and emission levels worsen. Engine emission legislations have forced manufacturers to improve their engine efficiencies, particularly at low speeds where low air/fuel ratios cause high smoke levels. The Holset integral wastegate turbocharger is a cost effective solution to this problem and for a small increase in complexity, a simple variable flow turbine housing has been achieved. Integral wastegate turbochargers have been available for passenger cars for many years. Holset has developed such a turbocharger with components designed for extended life equal to that of standard commercial vehicle turbochargers. The importance of correctly servicing the wastegate actuator mechanism A wastegate turbocharger requires accurate setting at point of manufacture. It is very important to adhere to setting limits when servicing the turbocharger, as failure to do so could result in turbocharger or engine failure. Effects of wrong setting Possible consequences if turbocharger boost pressure is too low:- • Engine runs fuel rich • Fuel consumption increase • Exhaust temperature increase • Smoke levels increase • Hydrocarbon levels increase • Risks of failing emissions tests • High cylinder temperature risks damage to engine pistons Possible consequences if turbocharger boost pressure is too high:- • Engine runs fuel weak (lean) • Nitrous oxide levels increase • Excessive boost overspeeds • Turbocharger bearing failure and turbocharger wheel fatigue problems • Increased cylinder pressure risks damage • Intercooler load increases causing engine to engine head gasket, pistons and valves to overheat, risking piston damage

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Holset Turbochargers OEM Service & Repair Manual

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