Turbo Charger

Turbo Charger
Technology
2007.01. 08
Cummins Korea
Introduction - Product World-Wide
U.K Holland
U.S.A Huddersfield - Holset Service
Memphis - Turbochargers
- Holset Service - Holset Service-
U.S.A
Charleston
- Turbochargers China
- Turbochargers
- Holset Service
Brazil India
- Holset - Turbochargers
Service - Holset Service
2
Product Range
HX83
HX82
Turbocharger Model Name
HX60/60W
HY55V
HX55/55W
HX50/50W
HY40V
HX40/40W
HY35W
HX35/35W
HY30W
HX30/30W Holset/MHI Range

HX Range
HX27W
HY Range
HX25/25W
0 100 200 300 400 500 600 700 800
3
Horse Power per Turbo
Typical Applications
4
Why Turbocharge
5
왜 터보를 사용하는가? (Why Turbocharge)
엔진에서 생성되는 파워는 공기 소모량과 관계가 있다.

(Power developed by an engine is related to air
consumption.)
과급 (+연료의 추가공급) = 추가 마력 (More Air MASS
(+ fuel) = More Power)
+ O2 = POWER
6
Adding Extra Fuel
연료만 추가 공급할 경우
(Excess Fuel Added to Engine)
7
O2
Increasing Engine Size
엔진 사이즈 or 터보부착?
(Increase the size of
engine or turbocharge?) 6cyl 6litre
120 HP
344 kg
4cyl 4litre
80HP
247 kg
4cyl 4litre Turbo
122 HP
286 kg
8
왜 터보를 사용하는가? (Why
Turbocharge)
Supercharging
Air
Theoretical Filter
increase
200hp to 275hp
Supercharger
Uses 50hp
Engine
X
275hp
Actual
225hp
9
Altitude Compensation
높은 고도에서 적어진 산소 높은 고도에서 밀도가 낮아져

그러나 같은 양의 연료분사 터보가 더 빨리 돌게 된다.
(Less O2 at high altitude is Turbocharger rotates faster
insufficient to burn all the to increase delivery of O2
fuel.) to engine.
출력감소 그리고 검은 매연 Clean emissions and power
Low power and black
smoke.
smoke
10
Why Turbocharge
Aftercooling
차가운 공기는 뜨거운 공기보다 밀도가 높다

(Cold air has a higher density than warm air.)
차가운 공기의 이송 = 보다 많은 산소 = 엔진 출력
증가 (Delivering cold air = more O2 per cylinder
= more engine power)
애프터쿨러는 온도를 낮춘다 Î 밀도를 증가

시킨다. (Aftercooling reduces the temperature
11
thereby increasing the density.)
Why Turbocharge
Aftercooling [Air to Water]
12
Why Turbocharge
Aftercooling [Air to Air]
13
Turbocharger Components
Major Components
Thrust
Journal Bearing Diffuser
Bearing
Bearing Housing Backplate
Bearing Thrust
Circlip Collar
Piston
Ring Seal
Piston
Ring Seal
Turbine
Wheel
Compressor
Heat Wheel
Shield
Turbine Oil Oil Compressor

Housing Deflector Slinger Cover
14
© Holset Engineering Co Ltd
Turbocharger Components
Turbocharger Identification
Check
Identification
3521538
D001120103
3521539
HX25W
15
© Holset Engineering Co Ltd..
How A Turbocharger Works
• The turbine housing is bolted

to the exhaust manifold of the
engine.
• The waste exhaust gasses are

used to rotate a turbine wheel
which is housed in the turbine
casing.
• The turbine wheel is connected

to a common shaft which in turn
rotates a compressor wheel.
16
• 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.
17
• As the air is sucked into the

compressor cover, it is forced
through a diffuser area.
• This compressors the air and

forces it into the engine
• This process causes the air to

increase in temperature,
sometimes upto 200 degrees C
18
• Front Wheel Clearance affects the

performance of the turbo.
• The smaller the FWC the better

the performance. Compressor Cover
Profile.
• The Compressor Wheel Bore must
be machined to tolerance / drawing.
• Over sized bore will affect the balance

of the turbocharger.
FWC
Compressor Wheel
Profile
Compressor Wheel Bore
19
Failure Diagnosis:
Dirt Ingress
Journal Bearing Clearances

(H1E)
C = Max 00.084mm (0.0033”)
C = E S 00.042mm (0.00165”)
Human Hair
(0.003”)
20
• The oil used in a turbocharger is

the same as that used for your
engine.
• The oil is used as both a lubricant

and a coolant.
• It is fed under pressure into the

bearing housing, through to the
journal bearings and thrust
system.
21
• The Journal Bearings are a free

floating rotational type.
To perform correctly, the journal

bearings should float between a film
of oil (i.e. between bearing & shaft,
& bearing & bearing housing.)
• Dirty oil, or blockages in the oil

supply holes can cause serious
damage to the turbocharger.
22
• Piston Ring Seals, can be found

at both ends of the turbocharger
• They are designed to keep the

exhaust pressure out of the
bearing housing, and the air
pressure out of the bearing
housing.
• The surface finish on both

Turbine & Compressor end bore
must be smooth and score free.
23
Summary
• What is the function of the

Turbine Housing ?

Compressor Housing ?

oil in the turbocharger ?
24
Failure Diagnosis:
Hot Shutdown
340 340
Bearing Temperature oC
Hot Shut Down
from Peak Torque 300
300
Temp Limit 1 min Idle
of
260 CF Oil 260
2 min Idle
220 3 min Idle 220
180 180
140 140
0 60 120 180 240 300 360
Time (secs)
25
Failure Diagnosis:
Why Turbochargers Fail.
• Infrequent or Improper Service 지정된 서비스를 무시
• Poor Quality Oil 저질 오일 사용
• Poor Quality Filters 저질 필터 사용
• Foreign Body Damage 이물질 인입
• Faulty Engine 엔진으로 부터의 영향
• Incorrect Turbocharger Assembly 조립불량
• Manufacturing Defects 제작시 결함
26
Failure Diagnosis:
What Happens When a Turbocharger Fails
What Problems Could be

Caused as a Result of
Turbocharger Failure ?
27
Failure Diagnosis:
What Happens When a Turbocharger Fails
터보챠져에 이상이 생기면 어떤 일이…

• Loss of power 출력감소
• Increase in Noise 소음증가
• Increased Wear 마모증가
• Rotating Assembly could Seize 회전부의 정지
• Wheel Rub on Housing Profiles 휠과 하우징의 마찰
• Turbine or Compressor Blade Damage 날개의 손상
• Compressor end Oil Leak 오일누유
• Turbine end Oil Leak 오일누유
28
Failure Diagnosis:
Common Causes Of Turbocharger Failure.
What are the Most Common

Causes of Turbocharger Failure ?
29
Failure Diagnosis:
Common Causes Of Turbocharger Failure
• Oil Delay 오일공급 지연 (3 ~ 4 초 후 공급)
• Oil Starvation 오일공급부족 (10 초가 지나도 부족)
• Ingress of Dirt 더러운 오일
• Overheating 과열
• Rotor Unbalance 로터의 균형파괴
30
TURBOCHARGER FAILURE
ANALYSIS
31
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 HOLSET

problem or a customer / end user problem.
If the problem is HOLSET’S 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.
32
Customer Reported Faults
Leak oil
Broken
Low power
Noisy
Gas leakage
Seized
High oil consumption
Broken shaft
Smoke
33
Failure Analysis
We require information from :

a) Customer
b) Distributor
This will help us analyse a warranty claim.
What information do we require ?

How will it help when analysing a warranty claim?
34
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
35
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
36
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
37
Warranty Analysis
How can we determine the root cause of

the problem?
38
The following presentation will help you diagnose turbocharger
warranty claims.
It is recommended that safety glasses are worn when

disassembling the turbocharger
39
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.
40
Customer Responsibility
41
Check for compressor end foreign object damage by looking in
the intake.
AIR INTAKE
42
Foreign Object Damage Compressor
End
Cause : Rags,wrenches,nuts,screws,parts from the intake filter.
Damage to the blade tips
43
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
44
Foreign Body Turbine End
45
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 Holset Service Data Sheet (current version can be
downloaded from www.Holset.co.uk - Parts & Service section)
46
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.
47
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.
48
Remove the shaft & wheel,check for

any heat discolouration and any wear
on the shaft.
49
Remove the circlip
Remove the oil seal plate
Remove the O-ring seal
50
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
51
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.
52
Silicone Applied to Oil Inlet Gasket
Do not use
silicone
53
Foreign Body Blocking the Oil Supply
to the Thrust Bearing
Silicone blocking oil to the thrust

bearing
54
55
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.
56
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).
57
Oil Dirt Ingress
Cause :
Service intervals
overdue
Cleanliness during
service
Poor quality oil
Poor quality filters
58
Oil Dirt Ingress
Shaft wear from oil dirt ingress
59
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.
60
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
61 Lack of priming
Oil Starvation
Cause : Oil pump failure

Broken oil feed pipe
No oil in engine.
62
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.
63
Hot Shutdown
Check for sign of heavy carbon deposits in the bearing

housing,on the shaft & wheel piston ring boss area. This can be
the cause of hot shutdowns, lack of maintenance or poor quality
oil.
Laquering of the shaft is also common in cases of hot shutdown

failures.
64
Hot Shutdown - Overheating
65
Failure Diagnosis:
Hot Shutdown
340
Hot Shut Down

from Peak Torque
300
Temp Limit 1 min Idle
of
260 CD Oil 2 min Idle
220 3 min Idle
180
140
0 60 120 180 240 300 360
Time (secs)
66
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.
67
REMEMBER TO FULLY ANALYSE ALL

PARTS OF THE
TURBOCHARGER,BEFORE MAKING A
CONCLUSION ON CAUSE OF FAILURE.
68
Summary of Distributor or Customer
Responsibility
Correct replacement of turbocharger
If repaired or remanufactured the distributor takes responsibility

for all the manufacturing / assembly processes
Fitting of correct parts ( Turbine Housing etc )
Holset distributor would be expected to use genuine HOLSET

replacement parts
Use of copy parts would invalid any HOLSET warranty
69
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.
70
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).

71
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.
72
Oil Leakage
Restriction
73
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.
74
Compressor End Oil Leakage
75
Compressor End Oil Leakage
76
Oil Leakage
77
Oil Leakage
WARNING - DO NOT operate the engine if you

suspect any oil has collected in the engine intake
or charge cooler.Drain and clean before engine
start up to avoid engine runaway after full warm
up
78
Customer Support
Preventative Maintenance
How to fit a Replacement Turbocharger
79
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.
80
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
81
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
82
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
83
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
84
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
85
Check that the oil inlet and drain flanges are clean and free from
obstruction.
Replace the gaskets
86
Replace the oil and filter using only OEM recommended parts
and specified oil grade & classification.
87
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.
88
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
89
Connect the oil drain line and then fill the turbocharger oil feed
hole with clean engine oil. Slowly rotate the rotor by hand.
90
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.
91
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.
92
Holset Technical Literature on the Web
93
Holset Technical Literature on the
Web
94
Web
95
Web
96
Any Questions?
Thank You
97

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Turbo Charger

HX30/30W Holset/MHI Range

0 100 200 300 400 500 600 700 800

엔진에서 생성되는 파워는 공기 소모량과 관계가 있다.

높은 고도에서 적어진 산소 높은 고도에서 밀도가 낮아져

차가운 공기는 뜨거운 공기보다 밀도가 높다

애프터쿨러는 온도를 낮춘다 Î 밀도를 증가

Turbine Oil Oil Compressor

• The turbine housing is bolted

• The waste exhaust gasses are

• The turbine wheel is connected

• As more gas passed through

• As the turbine wheel increases in

• The faster the wheels spin the,

• As the air is sucked into the

• This compressors the air and

• This process causes the air to

• Front Wheel Clearance affects the

• The smaller the FWC the better

• Over sized bore will affect the balance

Compressor Wheel Bore

Journal Bearing Clearances

• The oil used in a turbocharger is

• The oil is used as both a lubricant

• It is fed under pressure into the

• The Journal Bearings are a free

To perform correctly, the journal

• Dirty oil, or blockages in the oil

• Piston Ring Seals, can be found

• They are designed to keep the

• The surface finish on both

• What is the function of the

• What is the function of the

• What is the function of the

Hot Shut Down

220 3 min Idle 220

What Problems Could be

터보챠져에 이상이 생기면 어떤 일이…

What are the Most Common

• Oil Delay 오일공급 지연 (3 ~ 4 초 후 공급)

• Oil Starvation 오일공급부족 (10 초가 지나도 부족)

• Ingress of Dirt 더러운 오일

• Rotor Unbalance 로터의 균형파괴

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

We also need to determine who is responsible.

We need to prevent a reoccurrence - whether it is a HOLSET

If the problem is HOLSET’S we need to ‘fix’ it.

If the problem is the customer’s we need to work with and

We require information from :

This will help us analyse a warranty claim.

What information do we require ?

SUMMARY INSPECTION REPORT NO

HOLSET TURBOCHARGER SUMMARY INSPECTION REPORT

SUMMARY INSPECTION REPORT NO 01

How can we determine the root cause of

It is recommended that safety glasses are worn when

Check for damage to the external surfaces,concentrating

Check axial and radial clearances. Clearances can be found in

Remove the core assy

Remove the shaft & wheel,check for

Remove the circlip

Remove the oil seal plate

Remove the O-ring seal

Check for wear or score marks