Holset HY55V Service Manual - Genuine Holset Turbochargers
Contents
1. Warning A Always wear safety glasses Valve current draw can be checked by inserting ammeter in the supply to valve pin 7 and applying 12 Volt DC from pin 7 to ground Pin 12 Ammeter should indicate current draw of 1 5 Amp at 20 C Where current draw exceeds this value replace valve in accordance with Valve Removal and Refitting Valve Removal and Refitting To remove and replace valve always refer to engine manufacturer s instructions Removing Valve Warning A Pneumatic connections may be pressurised Always ensure engine keyswitch is in off position before taking service action and use face protection Caution A Where it is necessary to break inlet or outlet pneumatic connections it is essential that open pipes and connections are protected from dirt and fluid entry using clean rubber plugs Never apply thread tape during re assembly of adapters or hoses to avoid debris ingress Refitting Valve Caution A A Always check part number and date code of Icon valve Incorrect valve will affect engine performance A REMOVE E lt gt QUITAR Caution A New valves are fitted with a protective adhesive Qa label over pressure sensor breather For correct valve function adhesive label must be removed after fitting valve painting 4 22 TURBOCHARGERS2. 4 18 Icon Control Valve css usas Heke pal pa ee eke Gn a aba wed ed sat 4 19 6 Service Data Sheets VG Range Service Data Sheets HY55V Service Manual Introduction About the Manual The procedures in this manual were developed to instruct in the correct overhaul of the designated Holset turbochargers 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 This section is not available for this turbocharger range at the present time Section 6 quantifies build data to ensure the turbocharger will continue to operate
3. 9D A 9 ecl 4 6 HY55V Service Manual Component Testing and Replacement Safe Lifting Methods H Variable geometry turbochargers weigh up to 33 kg 72 Ib and include sensors electrical wiring and connectors which are sensitive to handling On some specifications a drilling is provided in the bearing housing for a lifting eye to aid mechanical handling It is designed to be used exclusively for turbocharger removal and installation It must not be used for engine or engine component lifting Doing so will damage the turbocharger and could cause failure of the lifting eye resulting in personal injury When lifting the turbocharger manually always get assistance to avoid either back strain or consequential injury caused by dropping the unit Mechanical Handling M12 X 1 75 Some turbocharger specifications have option to fit a A I lifting eye to ease handling Always torque tighten lifting eye to value specified in Service Data Sheet Always ensure that lifting eye is fitted with a warning tag Warning A For lifting turbocharger only Do not use for engine or engine component lifting When lifting eye is fitted always use mechanical hoist to support weight of turbocharger during disassembly A and reassembly Caution A These turbochargers weigh up to 33 kg 72 Ib and A include sensors electrical wiring and connectors which are sensitive to handling
4. Control Valve Removal amp Replacement Fixing and position of control valve is dependant on engine application Process of replacement will be included in engine manual Pressure Guage Dcon valve can be cleaned when installed using pressure wash or steam cleaning equipment Vo Warning A Always wear safety glasses SS d Qs Control Valve Caution A pe en Battery A 12 Vor24V Always ensure the valve is non operational but Ela Air Supply Depending on vehicle system connected pneumatically and electrically during om o Inporan cleaning Warning A Care must be taken when breaking pneumatic connections as these may be pressurised Caution A Where it is necessary to break inlet outlet and capsule pressure sensor pneumatic connections it is essential that open pipes and connectors are protected from dirt and fluid entry using clean rubber plugs 4 18 HY55V Service Manual Icon Control Valve Valve Air and Electric Connections Do not disconnect icon valve electrically or pneumatically at this stage The Icon valve has three pneumatic ports Port1 Air supply port M12 x 1 5 Port2 Pulse Width Modulated PWM actuator supply port M12 x 1 5 Port 3 Exhaust port with shroud plate There are three active pins in the connector Pin 7 Supply voltage 9 to 32 Volt DC Pin 9 PWM input signal Pin 12 Ground voltage 0 Volt Valve Functions Icon valve pneumatic
5. Manual Handling When no lifting eye is fitted always seek assistance to support weight of turbocharger Eo gt gt 4 7 HY55V Service Manual Bearing Clearance Secure turbine housing and check thrust clearance using dial gauge Ensure clearance is within MIN and MAX valuesspecified in Service Data Sheet If axial clearance does not meet specification replace turbocharger Warning A Titanium compressor wheel edges are sharp Handle with care Check radial movement at compressor impeller nose using dial gauge Ensure movement is within MIN and MAX TIR Total Indicator Reading values specified in Service Data Sheet If radial movement does not meet specification replace turbocharger Warning A Turbochargers and installation parts are heavy Always refer to Safe Lifting Methods before removing or refitting bio Bo ap Component Testing and Replacement Y H 4 8 HY55V Service Manual VG Actuator Checks Warning A Always wear safety glasses Caution A Actuator movement and leak checks should be carried out on engine If turbocharger removal is necessary it will require Drainage of water system Disassembly of oil circuit Disconnection of sensors Warning A Turbochargers and installation parts are heavy Always refer to Safe Lifting Methods before removing or refitting Caution A During VG actuator checks and replacement it
6. 1 4 Installation Data 2 365 esse epee ee a See nes EE me Weed ee 1 6 Installation Checklist 1 7 SymbOlS 2 2 2 ne etsy wa he ea oN Ber ee Ca 1 8 2 Component Identification Turbocharger Identification 2 1 Dataplate ss ti A Bint de es octet Ree te EN 2 1 Installation Options 04 240 sea ee Has ee eee eee 2 2 Exploded View 2 3 Component List 2 4 3 Troubleshooting and Diagnosis Fault Finding Charts 3 1 4 Component Testing and Replacement Service Tools casais Seas Lei OA ise eee Medial Mate Oia aes 4 1 On Engine Checks 4 3 Safe Lifting Methods 4 7 Bearing Clearance 4 8 VG Actuator Checks 4 9 VG Actuator Removal and Checks 4 11 VG Actuator Replacement 4 13 VG Actuator Replacement Check 4 14 Speed Sensor Check and Removal 4 15 Speed Sensor Replacement 4 17 Dcon Control Valve
7. Caution A Orientation of the turbine housing of a variable geometry turbocharger is factory set Any attempt to re orientate the housing can cause severe damage to the VG mechanism and may void warranty Caution A This variable geometry turbocharger has been factory balanced using the core balance process Service overhaul repair must be carried out by Holset Engineering to ensure the variable geometry system is correctly rebuilt It is important to note that operating a turbocharger with rotor or core balance level greater than design limits could cause turbocharger or engine failure Caution A In the event of a suspected variable geometry turbocharger malfunction symptoms which may include low power and black smoke it is important to avoid potential progressive engine damage The vehicle should be taken out of service and towed to an appropriate repair facility as soon as this can be accomplished without sacrificing the safety of the operator and or passengers HY55V Service Manual Introduction Notes Cautions and Warnings Note Holset turbochargers can be remanufactured using recovered parts Where it is necessary to dispose of components or whole turbochargers an environmentally responsible process such as recycling should be used with due regard to local laws Note Holset Service receives many turbocharger returns that are no fault found Before assuming the turbocharger is not performing to specification always refer t
8. Engine Overheats Turbocharger noisy Poor acceleration Reduced braking Coolant leak Actuator rod not moving Check for air leaks and change clips and hoses as appropriate If actuator works with e e separate air supply check control valve If no actuator movement confirmed replace actuator If no movement with new actuator replace turbocharger VG mechanism artiaily Jammen Refer to Engine Control Unit ECU diagnostics for posible fault code data Check for air leaks and change clips and hoses as appropriate If air system OK check actuator 6 0 0 10 movement If full and free movement not confirmed replace actuator If partial movement with new actuator replace turbocharger Actuator loose or damaged Refer to ECU diagnostics for possible fault code data Check for damage to actuator bracket and fasteners If mechanical installation is OK check actuator movement If full oo 0 and free movement not confirmed replace actuator If partial movement with new actuator replace turbocharger Actuator air feed lines or connectors leaking Check for air leaks and change clamps and hoses as appropriate If actuator air system J 0 OK refer to general turbocharger fault finding chart No speed signal e Check sensor connections If pin resistance measurement is incorrect replace sensor e elo e e Where sensor may have been overheated check ECU diagnostic fault codes and if necessary replace sensor Intermittent or
9. Holset HY55V Service Manual Part No 4029531 Rev 03 Effect date 07 06 Ref JV KD Holset Aftermarket Croset Avenue Huddersfield West Yorkshire HD1 6SE www holsetaftermarket com Copyright 2006 Cummins Turbo Technologies Ltd All rights reserved Holset and VGT are registered trademarks of Cummins Turbo Technologies Ltd
10. s dataplate which will be found on the compressor housing or 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 HY55V Service Manual Introduction Description and Operation of Turbocharger 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 Variable Geometry Turbochargers VGT The Need for Variable Geometry The turbocharger on your vehicle s engine is of a very advanced type which varies the effective size of its turbine in response to the driver s demands Under all
11. Note 100 kPa 1 bar 14 5037 Ibf in2 psi HY55V Service Manual Introduction Installation Checklist 1 10 11 12 18 14 15 16 17 18 19 20 21 22 28 24 25 Always understand why the original turbocharger needs replacing before fitting another unit Check the turbocharger dataplate to ensure the Part No is correct for the engine application Check the engine exhaust intake and aftercooler systems are clean and without obstruction i e free from oil gasket pieces dust dirt carbon or foreign objects Replace the oil and air filters using replacement parts specified by the equipment manufacturer Change the engine oil using the type specified by the engine manufacturer Check that the turbocharger oil inlet and drain pipes and connectors are clean free from obstruction and will not leak under pressure Before re installing flexible pipes always ensure any burnt on lacquer or other adhered material is removed from internal bores If in doubt always fit new pipes Check that the coolant pipes of water cooled bearing housing applications and connectors are clean free from obstruction and will not leak under pressure To pre lube the turbocharger bearings pour some clean engine oil into the oil inlet and rotate the turbocharger rotor assembly by hand Check that the exhaust manifold flange is flat and undamaged Mount the turbocharger on the flange and check that the turbine inlet ga
12. Data Sheet Caution A It is recommended NOT to re use original fastener Where original fastener must be used it is important threads are clean and thread locking compound is applied Fastener torque must be applied within time specified by thread lock manufacturer Component Testing and Replacement Y H 4 17 HY55V Service Manual Component Testing and Replacement Dcon Control Valve H Control valve is remote from turbocharger It is ER connected pneumatically to VG actuator and electrically ZAN Bontrol Valve to engine control module ECM Valve controls pressure applied to actuator in response to signals sent from ECM Where ECM signals a control valve error check wiring harness is good If error persists check contol valve operation To check electrically disconnect control valve at its electrical connector Use multi meter to check resistance between pins 1 and 2 Resistance for a 24 Volt control valve should be 24 5 0 5 Ohm at 20 C If engine diagnostics indicate a problem with valve it must be serviced by replacement as it contains no serviceable parts To check electrically disconnect the control valve at its 12 V Control Valve electrical connector Use a multi meter to check resistance between pins 1 and 2 The resistance for a 12 Volt control valve should be 6 5 0 5 Ohm at 20 C Contact your approved agent for parts and availability
13. Smoke High Oil Consumption Turbocharger Noisy Cyclic Sound from the Turbocharger Oil Leak from Compressor Seal Oil Leak from Turbine Seal e e an O E gt cc O W Dirty air cleaner Clean or replace element according to manufacturer s recommendations oo oo Restricted compressor intake duct Remove restriction or replace damaged parts as required Restricted air duct from compressor to intake manifold Remove restriction or replace damaged parts as required O O Restricted intake manifold e Refer to engine manufacturer s manual and remove restriction Air leak in feed from air cleaner to compressor e Replace seals gaskets or tighten fasteners as required O O O Air leak in feed from compressor to intake manifold Replace seals gaskets or tighten fasteners as required ojo e oo Air leak between intake manifold and engine e e cio Refer to engine manufacturer s manual and replace gaskets or tighten fasteners as required Foreign object in exhaust manifold from engine Refer to engine manufacturer s N and remove obstruction oo o Restricted exhaust system e e Remove restriction or replace damaged parts as required Exhaust manifold cracked gaskets blown or missing eo e Refer to engine manufacturer s manual and replace gaskets or damaged parts as required Gas leak at turbine inlet exhaust manifold joint eo e Replace gasket or tighten fasteners as required Gas leak in du
14. conditions of driving the turbine is electronically controlled to change the amount of air supplied to the engine to ensure maximum performance lowest fuel consumption and minimum exhaust emission levels When rapid vehicle acceleration is required the turbocharger will produce air for the engine more quickly than a conventional unit thus eliminating turbocharger lag and giving improved vehicle drivability As the engine and turbocharger run in and eventually start to wear the combination of the variable turbine and its associated electronic control will change its characteristic to keep to the original performance and emission levels over a wide range of ambient temperatures and altitude The Importance of Correctly Installing a Variable Geometry Turbocharger VGT The bearing housing of your turbocharger contains an internal water cooled jacket The purpose of this is to reduce the operating temperature of the housing to improve the operating environment of the speed sensor and reduce the high soak temperatures produced when the engine is switched off after being heavily loaded The addition of water cooling has meant that there are two extra pipe connections to the turbocharger to bring water to the housing and to take it away It is important to observe the correct installation of these pipes so that the circulation of the water is in the correct direction or the effectiveness of the cooling system will be lost and severe damage may res
15. estos simbolos su significado se espcifica en la parte inferior IREDOLFTSFOSBSPP do S SE amp ADVERTENCIA Procedimientos de Mantenimiento o Servicio que al no seguirse resultar n en da os personales o p rdida de vida ATENCION Procedimientos de Mantenimiento o Servicio que al no seguirse al pie de la letra resultar n en el da o o la destrucci n del turbosobrealimentador Indica un paso de REMOCION o DESMONTAJE Indica un paso de INSTALACION o MONTAJE Se requiere INSPECCION LIMPIESE la pieza o el montaje Ejecutese una MEDICION mec nica o del tiempo LUBRIQUESE la pieza o el montaje Indica que se dar una LLAVE DE TUERCAS o el TAMA O DE HERRAMIENTA APRIETESE hasta un par torsor especifico Ceri rese de que est n alineadas las marcas de balance en el rotor EJECUTESE una MEDICION el ctrica Para informaci n adicional refi rase a otro emplazamiento de este manual o a otra publicaci n anterior Favor de siempre llevar ropa protectora Indica que los componentes pueden ser pesados Acceso a Sitio Web para localizar su agente Holset m s cercano Ira la tabla de materias 1 10 HY55V Service Manual Introduction Symboles Fran ais Les symboles suivants sont utilis s dans ce manuel pour aider communiquer le but des instructions Quand l un de ces symboles apparait il voque le sens d fini ci dessous SREACETSFO E DP do gt SEP ATTENTION DANGER Proc dures de maintenance
16. is necessary to break pneumatic connection between control valve and actuator It is essential that open pipe is protected from dirt and fluid entry Warning A Pneumatic connections may be pressurised Always ensure engine keyswitch is in off position before taking service action and use face protection Refer to engine manual for details of hose threaded connection Remove hose connector from actuator air inlet Warning A Avoid touching VG mechanism as finger injury may result from sudden movement of assembly when air is supplied Connect and secure hose from regulated air supply to actuator air inlet Caution A Ensure regulated air supply is dry and filtered to avoid damage to actuator piston and actuator o ring seals ob OPP BL a a AL EDR x a S Component Testing and Replacement 4 9 HY55V Service Manual Warning A Always wear safety glasses Apply 300 kPa 43 5 Ibf in maximum 450 kPa 65 Ibf in from regulated air supply and ensure actuator rod moves lever Warning A Avoid touching VG mechanism as finger injury may result from sudden movement of assembly when air is supplied Control regulated air supply between O and 300 kPa 43 5 Ibf in and confirm actuator travel is within permissible range specified in Service Data Sheet Whilst air pressure is still applied at 300 kPa 43 5 Ibf in c
17. is in off position before taking service action and use face protection Caution A Visual checks and audible checks for air leaks may be completed safely with running engine Alternatively apply an external air source Actuator 7 16 20 UNF 5 8 in Pipe Fitting 9 16 18 UNF Check for air leaks at end plates and air hose connectors ensuring torque meets engine manufacturer s recommendation AOOPE J When replacing air inlet adapter torque tighten to value specified in Service Data Sheet OLY Caution A If actuator leaks air however little it must be replaced Using damaged actuator will result in inferior performance of turbocharger and engine Check for air leak at base of actuator housing Warning A Actuator is not a serviceable item Do not disassemble actuator as release of in built separating forces may cause personal injury DD Temperature Sensor M14 x 1 5 13 16 in Pressure Plug M14 x 1 5 6 mm Allen Key Air leakage passed sensor and or pressure plug can lead to unfiltered air ingress to compressor It may be possible to detect leakage from evidence of dirt lines in sensor plug bores or on visible compressor housing internal surfaces Torque fasteners to value specified in Service Data Sheet gt Where leakage continues replace temperature sensor and or pressure plug If compressor housing threads are damaged replace turbocharger g d Warning Turbochargers and installatio
18. ou d entretien qui si elles ne pas observ es correctement auront pour r sultat des l sions corporelles ou un d c s MISE EN GARDE Proc dures de maintenance ou d entretien qui si elles ne sont pas observ es strictement auront pour r sultat de causer des d g ts au turbocompresseur ou de conduire a sa destruction Indique une op ration de DEPOSE Indique une op ration de MONTAGE L INSPECTION est n cessaire NETTOYER la pi ce ou l ensemble EFFECTUER une MESURE m canique ou de temps GRAISSER la pi ce ou l ensemble Indique qu une DIMENSION DE CLE ou D OUTIL sera donn e SERRER a un couple sp cifique S assurer que les rep res d quilibrage sur ensemble de rotor sont align s EFFECTUER une MEASURE lectrique Se reporter a un autre endroit dans ce manuel ou a une autre publication pour obtenir des information plus completes Il faut toujours mettre v tements de protection Indique que les composants peuvent tre lourds Acc s au site Web pour trouver agent Holset le plus proche Aller au sommaire 1 11 HY55V Service Manual Introduction S mbolos Portugu s Os s mbolos a seguir ser o utilizados neste manual para facilitar a comunica o das instru es e seue significados est o d scritos abaixo IREDLFTSFOSBSPP do gt SE P ATEN O Os procedimentos de Manuten o ou Servi os que n o forem seguidos correctamente resultar o em ferimentos pessoais ou risc
19. system is not fitted with a shut off valve When Icon valve is activated electrically in key on engine start condition it exhausts over PWM duty cycle activated by Engine Electronic Control Module ECM With key off engine stopped valve isolates air supply and will not exhaust Warning A Always wear Safety glasses Warning A Visual checks and audible checks for valve exhaust air and air leaks may be completed safely with a running engine Caution A Icon valve has small but constant air bleed during engine operation including operation at low idle condition To maintain system pressure air compressor and dryer will cycle All Icon valves have same physical dimensions and features It is very important to quote Customer Part Number and Date Code when re ordering valve to ensure replacement valve is preset to specified performance characteristic Caution A Always check part number and date code of Icon valve Incorrect valve will affect engine performance DEPP Ol Component Testing and Replacement a g F AirTanl Engine Speed Throttle Demand Inlet amp Tem Exhaust Manifold Pressure ON ik D fold ture E
20. thermal and mechanical loads AOLO Warning A Turbochargers and installation parts are heavy Always refer to Safe Lifting Methods before removing or refitting Cracking of inlet duct requires turbocharger replacement se Check flange for cracks and ensure flatness is within 0 1 mm 0 004 in Acceptance and rejection guidelines are shown in this illustration If exhaust gasket is available always ensure that any cracks lie within its sealing area BoD Check fastener hole diameter is not more than 1 5 mm larger than max thread diameter of fastener M12 x 1 75 A Check flange threaded holes with thread gauge A Coolant Leakage S N Bearing Housing M18 x 1 5 19 24 mm Pipe Fitting 13 16 16 UN E Warning Water connections may be hot and pressurized Never take service action with engine running Protect face and hands from hot fluid leakage amp Repair leaks by refitting replacing adapters Where housing threads are damaged replace turbocharger Torque tighten adapters to value specified in Service Data Sheet Caution A Do not use sealant as this may affect performance of o ring seals 4 4 HY55V Service Manual Air Leakage Warning A Always wear safety glasses Warning A Pneumatic connections may be pressurised Always ensure engine keyswitch
21. Shroud k Plate Compressor Y Turbine El Te a Sliding Nozzle Ring and Vanes Operating Yoke Push Rods and Bushes The Holset Variable Geometry Turbine VGT system works by controlling the width of a nozzle guiding the gas flow into the turbine wheel Control is achieved using an air supply from the vehicle s auxiliary air reservoir The Engine Control Module modulates the supply pressure to the turbocharger pneumatic control cylinder actuator which acts on a rod and yoke system to slide the nozzle ring and blades relative to the fixed shroud plate This movement varies the area through which exhaust gas enters the turbine wheel blades Pneumatic Actuator N Control Air Pressure Sensor gt Optional Control Valve Electrical Control Line i Air Tank Valve Engine Speed Engine Control Module ECM Throttle Demand Inlet Manifold Pressure amp Temperature Contains pre set data on airflow requirements for any fuel quantity injected at any engine speed Exhaust Outlet Pressure Exhaust Manifold Pressure gt with built in safety features for excessive Turbochar so di a ger Speed Fuel Injection Pump Information a boost smoke or Le turbocharger speed Ambient Pressure amp Temperature e gt HY55V Service Manual Introdu
22. TURBOCHARGERS Holset HY55V Service Manual Copyright 2006 Cummins Turbo Technologies Ltd All rights reserved Holset and VGT are registered trademarks of Cummins Turbo Technologies Ltd HY55V Service Manual Foreword Foreword This publication was written to assist with turbocharger installation maintenance and overhaul It is not a warranty of any kind express 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 HY55V Service Manual Table of Contents Table of Contents 1 Introduction About th Manual sera ss ern TE eae eed a dip aba aay 1 1 How to Use the Manual 0000 cee eee eee 1 1 How to Order Holset Original Parts 1 1 Description and Operation of Turbocharger 1 2 General Information 1 2 Introduction to Variable Geometry Turbochargers 1 2 Notes Cautions and Warnings
23. Tools H The following special tools are recommended to perform procedures in this manual The use of these tools is shown in the appropriate procedure These tools can be purchased from your local Authorised Repair Location Part No Tool Description Tool Illustration Vehicle Battery Supply Multi meter Caution A All Service and Maintenance settings are shown in Holset s Service Data Sheet It is essential that these settings are used Common tools found in mechanic s tool box not included 4 2 HY55V Service Manual On Engine Checks Component Testing and Replacement Y H Variable geometry turbochargers have potential oil gas coolant and air leak paths They are fitted with sensors and an actuator which contain sensitive components When checking and correcting leaks it is essential that good practice and the correct tools are used to avoid damaging the turbocharger Oil Leakage Bearing Housing M14 x 1 5 19 mm Pipe Fitting 11 16 16 UN 2A Warning A Always wear safety glasses Replacement seals and adapters should be fitted without sealant as this can contaminate the oil Torque tighten adapter to value specified in Service Data Sheet It is important to avoid kinked or worn pipes during servicing and subsequent operation Flange fitting M8 x 1 25 Warning A Inlet oil is pressurized and outlet oil is hot Never take service action with engine running Protect face and hands from hot fluid leakag
24. action and use face protection Slacken failed joint and re tighten adapter or hose connection to torque specified by engine manufacturer Where leakage persists replace adapters or hoses in accordance with Valve Removal and Refitting Warning A If an o ring seal has been subject to fire always wear neoprene gloves when handling Caution A When breaking inlet or outlet pneumatic connections it is essential that open pipes and connections are protected from dirt and fluid entry using clean rubber plugs Never apply thread tape during re assembly of adapters or hoses to avoid debris ingress gt TN O gt d Sy AO gt gt J g 4 2 Component Testing and Replacement Hopp f X HY55V Service Manual Internal Leakage Warning A Always wear safety glasses If troubleshooting indicates control valve is jammed open or valve spring is damaged or broken it is possible to check using forward leakage test Insert O to 1500 kPa 0 to 200 Ibf in pressure gauge into actuator supply hose Port 2 Apply system pressure in range 700 to 1300 kPa 100 to 190 Ibf in to valve inlet Port 1 in key off valve closed position and check there is no pressure registered on gauge If pressure registers replace valve in accordance with Valve Removal and Refitting If troubleshooting in
25. ak in use Start the engine and run at idle speed for approximately 1 minute so that the oil supply system is fully operational Accelerate the engine and check that there are no leaks obstructions of air oil coolant gas under pressure Check that no hose or connection deforms under normal operation Before switching off the engine leave it running at idle speed for at least 1 minute to cool the turbine HY55V Service Manual Introduction Symbols Symbole Deutsch In diesem Handbuch werden die folgenden Symbole verwendet die wesentliche Funktionen hervorheben Die Symbole haben folgende Bedeutung gt RBOKMCK OSS DP do gt SEE WARNUNG Unterhaltungs und Wartungsverfahren m ssen genau befolgt werden da ein Nichtbeachten zu Personensch den oder t dlichen Verletzungen f hrt ACHTUNG Falls Unterhaltungs und Wartungsverfahren nicht genau beachtet werden kann der Turbolader dadurch besch digt oder zerst rt werden AUSBAU bzw ZERLEGEN EINBAU bzw ZUSAMMENBAU INSRPEKTION erforderlich Teil oder Baugruppe REINIGEN DIMENSION oder ZEITMESSUNG Teil oder Baugruppe OLEN WERKZEUGGROSSE wird angegeben ANZUG auf vorgeschriebenes Drehmoment erforderlich Sicherstellen daB die AUSWUCHTMARKEN an der Rotor Baugruppe richtig ausgerichtet sind Elektrische MESSUNG DURCHFURHREN Weitere Informationen an anderer Stelle bzw in anderen Handb chern Schutzkleidung mu immer getragen werden Deutet an da Teile s
26. chwer sein k nnen Website Verzeichnis mit Ihrem n chsten Holset H ndler Gehe zu Inhalt HY55V Service Manual Introduction Symbols English The following group of symbols have been used in this manual to help communicate the intent of the instructions When one of the symbols appears it conveys the meaning defined below IREDOLFSFOSBSPP do gt SE P WARNING Serious personal injury or extensive property damage can result if the warning instructions are not followed CAUTION Minor personal injury can result or a part an assembly or the engine can be damaged if the caution instructions are not followed Indicates a REMOVAL or DISASSEMBLY step Indicates an INSTALLATION or ASSEMBLY step INSPECTION is required CLEAN the part or assembly PERFORM a mechanical or time MEASUREMENT LUBRICATE the part or assembly Indicates that a WRENCH or TOOL SIZE will be given TIGHTEN to a specific torque Ensure that the BALANCE MARKS on the rotor assembly are in alignment PERFORM an electrical MEASUREMENT Refer to another location in this manual or another publication for additional information Please wear protective clothing at all times Indicates components may be heavy Website access to find your nearest Holset Agent Go to contents HY55V Service Manual Introduction Simbolos Espafiol Los simbolos siguientes son usados en estes manual para clarificar el proceso de las instrucciones Cuado aparece uno de
27. ct to an extensive review by Holset and formal approval this limit may be increased to 25 kPa 3 6 Ibf in if a catalytic convertor is fitted Exhaust brake applications are permitted to operate at a continuously rated pressure up to 450 kPa 65 3 Ibf in Holset has experience of instantaneous pressures up to 700 kPa 101 5 Ibf in but any application operating above 450 kPa 65 3 Ibf in must be referred to Holset for approval Oil should be filtered to 10 um with efficiency of 60 TWA Time Weighted Average 20 um with efficiency of 85 TWA Efficiency assessed using ISO Standard 4572 SAE J 1858 Always use filters recommended by the engine manufacturer The oil quality must be as specified by the engine manufacturer and will be a minimum API CD MIL L 2104C specification Improvement in life can be obtained by using super high performance diesel SHPD oils particularly where extended oil drain periods are used Normal oil temperature is 95 5 C 203 9 F It should not exceed 120 C 248 F under any operating condition Any pre lube oil must be clean and meet the minimum CD classification The orientation of turbine housing and bearing housing of a VG turbocharger is fixed During installation do not attempt to rotate these components as it may affect the operation of the VG actuating mechanism and may void any warranty Holset permits oil drain pipes to decline at an overall angle of not less than 30 degrees below
28. cting after turbine outlet e e Refer to engine manufacturer s manual and repair leak Restricted turbocharger oil drain line Remove restriction or replace damaged parts as required ee o Restricted engine crankcase breather Refer to engine manufacturer s manual clear restriction oo Turbocharger bearing housing sludged or coked Change engine oil and oil filter overhaul or replace turbocharger as required Fuel injection pump or fuel injectors incorrectly set cio e Refer to engine manufacturer s manual and replace or adjust faulty components as required Engine valve timing incorrect e Refer to engine manufacturer s manual for correct settings and adjust as required Worn engine piston rings or liners Refer to engine manufacturer s manual and repair as required 0 0 Burnt valves and or pistons Refer to engine manufacturer s manual and repair as required o 0 00 00e Excessive dirt build up on compressor wheel and or diffuser vanes Turbocharger damaged e Find and correct cause of failure or replace turbocharger as necessary Contact your local approved dealer 3 1 HY55V Service Manual Troubleshooting and Diagnosis Fault Finding Chart variable Geometry Turbine Intermittent engine braking Intermittent low power Engine does not run smoothly Low power at low engine speed i e a n x l o O Ww
29. ction Notes Cautions and Warnings Notes Cautions and Warnings are used in this manual to emphasise important or critical instructions Note Information which is essential to highlight Caution A Maintenance or Service procedures which if not strictly followed will result in damage or destruction of the turbocharger Warning A Maintenance or Service procedures which if not correctly followed will result in personal injury or loss of life Warning A The designated turbochargers weigh up to 33 kg 72 Ib On some specifications a drilling is provided in the bearing housing for a lifting eye to aid mechanical handling It is designed to be used exclusively for turbocharger removal and installation It must not be used for engine or engine component lifting Doing so will damage the turbocharger and could cause failure of the lifting eye resulting in personal injury When lifting the turbocharger manually always get assistance to avoid back strain or dropping the unit and consequential injury External parts include electrical wiring and connectors which are sensitive to handling Some models arefitted with titanium compressor wheels which have sharp edges and should be handled with care Warning A Some parts are manufactured in fluoroelastomers eg Viton or similar that require special treatment in the case of repair and service after fire Warning A Turbocharger surface temperature during operation can achieve 700 C 1300 F
30. ctuator rod is at rest and there is no risk of finger injury Apply 300 kPa 43 5 Ibf in maximum 450 kPa 65 Ibf in air pressure until actuator is moving freely over whole stroke Caution A Where progressive motion cannot be achieved it is probable that an element of variable geometry mechanism internal to turbocharger is damaged In this case replace turbocharger Warning A Turbochargers and installation parts are heavy Always refer to Safe Lifting Methods before removing or refitting Control regulated air supply between O and 300 kPa 43 5 Ibf in and confirm actuator travel is within permissible range specified in Service Data Sheet Remove air supply Sor d Polder POJAS Component Testing and Replacement A gt 4 14 HY55V Service Manual Speed Sensor Check and Removal Ge amp Disconnect sensor at electrical connector Using multi meter check the resistance between pins 1 and 2 is in range 200 to 2000 Ohm with sensor at 20 C Check pins 1 to 3 and 2 to 3 have very high min 1 MOhm resistance Where road spray dirt and fluid ingress has caused fouling or corrosion of speed sensor fastener apply penetrating oil in accordance with oil manufacturer s instructions A SS Warning A Always wear Safety glasses M6 8 mm Using s
31. dicates abnormal engine performance it is possible that dirt or debris is adversely affecting Icon valve performance Disconnect air supply and actuator supply hoses Ports 1 and 2 and insert O to 1500 kPa 0 to 200 Ibf in pressure gauges Apply system pressure in range 700 to 1300 kPa 100 to 190 Ibf in to valve inlet Port 1 in key on valve actuated open position Pressure difference across valve must not exceed 200 kPa 29 Ibf in If maximum pressure difference is exceeded replace valve in accordance with Valve Removal and Refitting Warning A Pneumatic connections may be pressurised Always ensure engine keyswitch is in off position before taking service action and use face protection Warning A If an o ring seal has been subject to fire always wear neoprene gloves when handling Caution A When breaking inlet or outlet pneumatic connections it is essential that open pipes and connections are protected from dirt and fluid entry using clean rubber plugs Never apply thread tape during re assembly of adapters or hoses to avoid debris ingress logde toger Component Testing and Replacement Air Supply 12Vor24V Depending on vehicle system Polarity not important Battery 12Vor24V Depending on vehicle system Polarity not important 4 21 HY55V Service Manual Component Testing and Replacement Valve Current Draw
32. e Replacement gaskets and flange fasteners should be fitted without sealant as this can contaminate the oil Torque tighten fasteners to value specified by engine manufacturer All outlet pipes should be free flowing without kinks and sharp bends and decline at an overall angle not less than 30 degrees below the horizontal M6 x 1 0 8 mm Speed sensor is sealed by an o ring and fastened using dry setscrew with patch sealant feature Always use new setscrew provided in Holset Service Kit when re fitting sensor Torque tighten sensor to value specified in Service Data Sheet Caution A Do not use sealant when fitting speed sensor as this may contaminate oil and bearings Caution VAN If leak occurs at actuation lever change turbocharger Warning A Turbochargers and installation parts are heavy Always refer to Safe Lifting Methods before removing or refitting DIO 9 g ay g OPP LoSDP 92 4 3 HY55V Service Manual Component Testing and Replacement Exhaust Gas Leakage Turbine housing flange leakage will cause soot formation on flange Check exhaust manifold to flange seal ensuring fastener torque meets engine manufacturer s recommendation Warning A Always wear Safety glasses Caution A Turbine housings can exhibit cracking when subject to excessive
33. er injury Spray crank journal lightly with penetrating oil before fitting actuator end link Caution A Do not use Lithium grease M8 10 mm Slide actuator end link on to crank journal and ease integrated bracket onto roll pin in bearing housing Insert two new dry actuator screws with patch sealant feature provided in service kit Refit end link retaining ring Always fit new cover plate 157 and short screw 120 so that the cupped edge wraps round actuator end link Torque tighten to value specified in Service Data Sheet Caution A Never refit thick zinc washer and existing bolt M8 13 mm Torque tighten actuator screws to value specified in Service Data Sheet Caution A It is recommended NOT to re use original actuator screws Where original fasteners must be used it is important threads are clean and thread locking compound is applied Fastener torque must be applied within time specified by thread lock manufacturer Component Testing and Replacement A A g A A SES 4 13 HY55V Service Manual VG Actuator Replacement Check Following installation it is necessary to check that actuator moves through complete stroke Warning A Always wear Safety glasses Ensure hose from dry regulated air supply is properly secured to actuator air inlet Warning A Avoid touching VG assembly until it is clear that a
34. es or adaptors leaking Check oil feed and return pipes and adaptors for leakage Check O ring seals and replace if necessary Tighten adaptors and if leak persists replace failed adaptors or pipes using Holset recommended parts Oil leakage from speed sensor Check O ring seal and replace if necessary Refit sensor and if leak persists replace speed sensor Bearing housing damaged If O ring or connector replacement does not resolve an oil leak the bearing housing tappings may be damaged requiring replacement of the turbocharger Where water connector replacement does not resolve a water leak the bearing housing tappings may be damaged requiring replacement of the turbocharger DIT 3 3 3 HY55V Service Manual Component Testing and Replacement Service Tools H The following special tools are recommended to perform procedures in this manual The use of these tools is shown in the appropriate procedure Part No Tool Description Tool Illustration Torque Wrench Regulated Air Supply g Steel Rule 13 mm Diameter Clean Rubber Plug u 0 1000 kPa 150 Ibf in Pressure Gauge 7 Dial Gauge and Dial Gauge Adapter Allen Key 6 mm A F Caution A All Service and Maintenance settings are shown in Holset s Service Data Sheet It is essential that these settings are used Common tools found in mechanic s tool box not included 4 1 HY55V Service Manual Component Testing and Replacement Service
35. heck actuator for leaks Use soapy water and small brush Small bubbles will appear if actuator is leaking If actuator is leaking it must be removed by reference to VG Actuator Removal Caution A If actuator leaks air however little it must be replaced Using damaged actuator will result in inferior performance of turbocharger and engine If actuator travel is not within permissible range specified in Service Data Sheet remove by reference to VG Actuator Removal Warning A Actuator is not a serviceable item Do not disassemble actuator as release of in built separating forces may cause personal injury Component Testing and Replacement Y H DP topp tode DP e 4 10 HY55V Service Manual Component Testing and Replacement VG Actuator Removal and Checks H Warning A Always wear safety glasses Where actuator movement is outside range or where actuator air leaks have been discovered it is necessary to remove actuator to continue with fault diagnosis If possible these procedures should be carried out on engine If removal of turbocharger is necessary it will require Drainage of water system Disassembly of oil circuit Disconnection of sensors Warning A A Turbochargers and installation parts are heavy Always refer to Safe Lifting Methods before lt rem
36. horizontal These turbochargers require a drain pipe of 19 mm internal diameter minimum which has integrated connectors To ensure oil drains into the engine under all operating conditions the return connection into the engine sump must not be submerged Crankcase pressure should be limited to 0 8 kPa 0 12 Ibf in Pressure above this level should be referred to Holset for further evaluation Closed crankcase ventilation CCV systems are known to operate at elevated pressure and all applications must be referred to Holset for approval Oil pressure must show at the turbocharger oil inlet within 3 4 seconds of engine firing to prevent damage to turbocharger bearing system A flexible supply pipe is recommended The minimum oil pressure when the engine is on load must be 210 kPa 30 Ibf in Normal maximum operating pressure is 400 kPa 58 Ibf in although 600 kPa 88 Ibf in is permitted during cold start up Under idling conditions pressure should not fall below 70 kPa 10 Ibf in Recommended oil flow ranges for these turbochargers are 2 3 litre min at idle and 3 5 4 5 litre min at maximum engine speed Recommended coolant flows for these turbochargers are 3 litre min at idle and 14 litre min at maximum engine speed Coolant hose design must permit flow to increase progressively with engine speed Do not use liquid gasket substances or thread sealant as any excess can enter the turbocharger oil and coolant systems to obstruct flow
37. n parts are heavy Always refer to Safe Lifting Methods before removing or refitting Bo Component Testing and Replacement Y H HY55V Service Manual Visual Checks Make visual check for damaged or bent blades Caution A Never attempt to straighten blades Caution A Loosening rotation and or removal of turbine housing can cause severe damage to variable geometry turbine mechanism V band is protected by tamper evident clip and evidence of clip damage or removal may result in rejection of warranty claims Warning A Titanium compressor wheel edges are sharp Handle with care Make visual check for damaged and fouling of impeller blades Caution A Do not remove compressor housing as this may damage impeller Caution A Never attempt to straighten blades With intake system disconnected from compressor housing it may be possible to check visually for excess bearing axial and radial clearances If light finger pressure causes contact between compressor or turbine wheel and respective housing replace turbocharger If in doubt turbocharger must be removed from engine to check bearing clearance against recommended values specified in Service Data Sheet Warning A Turbochargers and installation parts are heavy Always refer to Safe Lifting Methods before removing or refitting Component Testing and Replacement
38. ngine Control Module ECM Contains pre set data on airflow requirements for any fuel quantity injected at any engine speed with built in safety features for excessive boost smoke or turbocharger speed Exhaust Outlet Pressure Turbocharger Speed Date Code Customer Part Number 4 19 HY55V Service Manual Valve Cleaning Icon valve can be cleaned when installed using pressure wash or steam cleaning equipment Warning A Always wear Safety glasses Caution A Always ensure valve is non operational key off but connected pneumatically and electrically during cleaning Normal Installed Operation Icon valve is fitted with shrouded exhaust port In any key on engine operating condition port will be active and a whistling hissing sound will be heard This represents normal valve operation In key off engine stopped condition there will be no exhaust air whistle Warning A Visual checks and audible checks for valve exhaust air and air leaks may be completed safely with a running engine External Leakage M12 x 1 5 17 mm In key on engine operating condition check for leakage at inlet and outlet hose connections Identify leaking joint and move to key off condition Warning A Pneumatic connections may be pressurised Always ensure engine keyswitch is in off position before taking service
39. noisy speed signal o Check sensor with multimeter If either resistance measurement is incorrect replace sensor Where sensor may have been overheated check ECU diagnostic fault codes and 0 0 O if necessary replace sensor No control valve drive signal To ensure drive signal is being received from ECU check control valve operation If either 0 0 0 10 OVor battery voltage condition is incorrect replace control valve and refer to engine manual Intermittent control valve drive signal Refer to ECU diagnostics for possible fault code data Check control valve connection to o ECU If control valve condition at either O V or vehicle battery voltage is incorrect or if intermittent fault persists replace control valve whilst referring to engine manual No boost pressure signal P2 If the ECU diagnoses a boost pressure signal error refer to engine manual 00 0 No air inlet temperature signal T2 If the ECU diagnoses an air nlet temperature signal error refer to engine manual 0 00 O Incorrect actuator pressure If the VG system has an actuator pressure sensor which reads an incorrect actuator pressure signal the fault is likely to be with the shut off valve control valve or pressure e sensor itself Refer to engine manual for repair and replacement instructions for shut off valve and pressure sensor test and replacement Check and replace control valve whilst referring to engine manual Incorrect control valve
40. o actuator air inlet Control regulated air supply between O and 300 kPa 43 5 Ibf in and confirm actuator travel is within permissible range specified in Service Data Sheet Caution A Detached actuator stroke is greater than stroke when attached to VG mechanism Ensure correct range is read from Service Data Sheet If actuator travel is not within permissible range specified in Service Data Sheet replace by reference to VG Actuator Replacement Warning A Actuator is not a serviceable item Do not disassemble actuator as release of in built separating forces may cause personal injury If actuator travel is within permissible range specifiedi in Service Data Sheet use mole vice grips and light force to check linear travel of VG crank journal If pin does not travel smoothly within permissible range specified in Service Data Sheet replace turbocharger Component Testing and Replacement TI pop 10 20 30 40 50 60 70 80 4 12 HY55V Service Manual VG Actuator Replacement Service Actuator Kit 121 Warning A Always wear Safety glasses Connect clean dry regulated air supply to actuator air inlet and apply 100 kPa 14 5 Ibf in maximum 150 kPa 22 Ibf in pressure to release actuator pre load Warning A Avoid touching VG assembly until it is clear that the actuator rod is at rest and there is no risk of fing
41. o the engine diagnostic system and the troubleshooting diagnostic procedures of this manual HY55V Service Manual Introduction Installation Data 1 11 12 18 14 15 16 17 Holset Service receives many turbocharger returns that are no fault found Before assuming the turbocharger is not performing to specification always refer to the engine diagnostic system and the fault finding chart of this manual to make all the recommended health checks It is important that intake and exhaust systems are fitted in accordance with the recommendations of the Equipment and Engine manufacturers It is important not to overload the turbocharger by external attachments or forces The air filter must remove particles greater than 5 um at an efficiency of 95 and be of sufficient capacity to match the air consumption of the engine Recommended filters should always be used with a pressure drop indicator Intake systems must be tightened to the values specified by the Equipment and Engine manufacturers to withstand depressions up to 6 3 kPa 0 91 Ibf in Hose and clip connections of intake manifold systems must be capable of withstanding the turbocharger pressure ratio V band clamps are preferred and must be used above 3 1 pressure ratio Exhaust system connections must be tightened to the values specified by the Equipment and Engine manufacturers to be capable of operating at exhaust back pressures of up to 10 kPa 1 5 Ibf in Subje
42. ocket wrench and ratchet loosen and remove speed sensor screw Caution A Breaking sealed fastener joint may require significant torque It is essential that socket spanner is properly engaged on fastener to avoid inadvertent damage to speed sensor cable and connector resulting from spanner slip Extract speed sensor ensuring that o ring seal is removed with sensor This is conveniently achieved by tilting sensor as it exits recessed bore A QS Place speed sensor on clean surface to avoid collection of metal particles Component Testing and Replacement 0 H HY55V Service Manual Warning A Always wear safety glasses Caution A Removal of speed sensor leaves an open access to bearing housing It is essential that no dirt or fluids enter bearing housing cavity during speed sensor replacement Insert clean rubber plug Component Testing and Replacement Y H 4 16 HY55V Service Manual Speed Sensor Replacement Warning A Always wear safety glasses Remove clean rubber plug Prior to inserting speed sensor ensure it is clean and unable to collect metal particles as it is inserted Ensure o ring seal is in position on sensor body M6 8 mm Use new cap head screw with patch sealant feature provided in service kit 124 to fasten speed sensor flange to bearing housing Torque tighten setscrew to value specified in Service
43. os de vida AVISO Os procedimentos de Manuten o ou Servi o que n o forem rigorosamente seguidos resultar o em danos ou destrui o do carregador turbo Indica um passe de DESMONTAGEM Indica um passo de MONTAGEM Requer inspe o LIMPE a pe a ou conjunto Requer Medi o mec nica ou de tempo LUBRIFIQUE a pe a ou o conjunto Indica necessidade de APERTO TORQUEAR de acordo com o especificado Assegure se de que as MARCAS DE BALANCEAMENTO do conjunto eixorotor estejam alinhadas Requer medi o EL TRICA Procure em outra se o deste manual ou em publica o par obter informa es adicionais Por favor sempre utilize EPI Equipamento de Protecao Individual Indica que os componentes podem estar pesados Visite o Website para encontrar o seu Agente Holset mais perto V para Conte do 1 12 HY55V Service Manual Turbocharger Identification Dataplate Note The dataplate will be fitted to the compressor housing 8 The information from the dataplate must be quoted for service and parts support HY55V Component Identification Y H Made in Huddersfield England Assy 35XXXXX WARNING Ay mee or Serial XYYMMXXXXX unauthorised modification of this turbocharger may cause Customer damage or personal injury Use Type HY55V only as specified by Holset yp 55 2 1 HY55V Service Manual Component Identification Y H Installation Options T
44. oving or refitting SS y I Warning OS MA Pneumatic connections may be pressurised Always TT ap b 4 ensure engine keyswitch is in off position before taking service action and use face protection Sn Where road spray dirt and fluid ingress has caused E fouling or corrosion of the actuator integrated bracket fasteners apply penetrating oil in accordance with manufacturer s instructions M8 10 mm Loosen 2 actuator screws Connect clean dry regulated air supply to actuator air inlet and apply 200 kPa 29 Ibf in pressure to release actuator pre load between bracket and lever 4 11 HY55V Service Manual Warning A Always wear safety glasses M8 10 mm Warning A Rod may retract quickly when freed from pivot arm Avoid touching the VG assembly until rod is at rest and there is no risk of finger injury Remove and discard screw and cover plate zinc washer from crank journal Remove end link retaining ring Slide actuator rod off the crank journal Remove actuator screws and discard Remove actuator If crank journal is worn replace turbocharger Warning A Turbochargers and installation parts are heavy Always refer to Safe Lifting Methods before removing or refitting Refer to engine manual for details of hose threaded connector Connect and secure hose from regulated air supply t
45. sket fits properly without obstructing the gas passages Assemble the air intake and boost outlet connections Check that the connections are secure and will not leak in use Check the exhaust system is fitted using the original mounting arrangement provided by the equipment manufacturer Always re fit any supports brackets back in position to ensure the system is correctly supported Assemble the exhaust system to the turbine housing outlet Check that the gasket connection is secure and will not leak in use Assemble any coolant pipes and check that the connections are secure without obstruction and will not leak in use Assemble the turbocharger oil inlet pipe and check that the connection is clean secure and will not leak in use Check all clamps and fasteners are correctly tightened to the torque recommended by the equipment manufacturer Make the electrical connections between VG sensors and engine control module ECM Check the electrical connection between control valve and ECM Check the air connection between the vehicle auxiliary tank and control valve Connect the air pipe from the control valve to the actuator ensuring the pipe bore is clean and dry before fitment Make any ECM checks recommended by the engine manufacturer Crank the engine WITHOUT firing until engine oil flows out of the turbocharger drain flange Assemble the oil drain pipe and check that the connection is secure without obstruction and will not le
46. supply pressure Likely causes are malfunctions of shut off valve or control valve Refer to engine manual 0 6 o o ele for repair and replacement instructions for shut off valve Check and replace control valve whilst referring to engine manual a are f fitted If val ki likel ligh eck actuator pressure if sensor fitted If control valve sticking is likely cause spray light penetrating oil into control valve inlet Allow to lubricate the valve mechanical parts 0 0 0 oo Conduct pressure check If either O V or battery voltage condition is incorrect change valve whilst referring to engine manual 3 2 HY55V Service Manual Troubleshooting and Diagnosis Fault Finding Chart variable Geometry Turbine Continued Engine Lacks Power Engine Overheats Intermittent engine braking Intermittent low power Engine does not run smoothly Low power at low engine speed Turbocharger noisy Poor acceleration Reduced braking Coolant flow restricted Check coolant pipework and connections for damage Replace damaged bearing housing fittings using only Holset recommended parts Refer to engine manual for flow data and service instructions for all other connections and pipework Coolant pipework or connectors leaking Check coolant pipework and connectors for leakage Tighten connections and if leak persists replace failed connectors or pipes using Holset recommended parts Oil feed and return lin
47. 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
48. ult The Importance of Correct Operation of a Variable Geometry Turbocharger VGT A variable geometry turbocharger is controlled by the engine control module to optimise engine air fuel ratio for performance and emissions A malfunction may cause a mismatch between air and fuel supply which could lead to progressive engine damage It is important that any operating symptom which indicates incorrect turbocharger operation is dealt with immediately by taking the unit safely out of service HY55V Service Manual Introduction The Advantages of a Variable Geometry VGT M Turbocharging System You may already have experience of the effect of a Wastegate turbocharger on the performance of your vehicle The advantage of Variable Geometry over a Wastegate system is that all the exhaust gas flows through the turbine wheel to increase net turbine power output In addition turbine power can be set to provide just sufficient energy to drive the compressor at the desired boost level wherever the engine is operating Speed and pressure sensors feedback information to the Engine Control Module to provide the necessary control As the name suggests a Wastegate turbocharger allows exhaust gas to by pass the turbine wheel This by passed gas contains energy which is lost to the turbine wheel Wastegate turbochargers have no feedback controls Pneumatic Control Cylinder Control Air gt Air Inlet Fixed gt
49. ype A 2 2 HY55V Service Manual Component Identification Exploded View HY55V H NAM AN NN Y SS 0 q Ph De N A 0 G Note Exploded views represent a generic build standard Parts may be added or subtracted in specific applications 2 4 HY55V Service Manual Component List HY55V Item No 121 126 159 27 122 92 106 77 129 123 53 113 114 105 115 124 112 120 27 144 156 158 27 103 27 Note Description VG Actuator Kit comprising VG Actuator fitted with Adapter Air Inlet fitted with O Ring Seal VG Actuator Fittings Kit comprising Roll Pin Screw Actuator Retaining Ring End Link Sacrificial Anode VG Bearing Housing Seals amp Adapter Kit Water amp Oil comprising Gasket Oil Outlet Adapter Oil Inlet fitted with O Ring Seal Oil Inlet Connector Male Water fitted with O Ring Seal Water Speed Sensor Kit comprising Speed Sensor Cap Head Screw O Ring Seal Control Valve Eye Bolt Bolt Temperature Sensor fitted with O Ring Seal Pressure Plug fitted with O Ring Seal Exploded views may not contain all listed components Component Identification 0 H Quantity 1 1 bh NN NN ac gt DD NN on a 2 4 HY55V Service Manual Troubleshooting and Diagnosis Fault Finding Chart an Applications Poor Transient Response Engine Lacks Power Black Exhaust Smoke Blue Exhaust
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