HX35/40 - The Wright Place

1 Copyright 1998 Holset Engineering Co. rights reservedPart No. 3580800 Effect date Repair ManualturbochargersFor updates of this manual please visit publication was written to assist field personnel with basic overhaul and rebuilding of the Holset HX30/35 specifications and rebuild information in this manual is based on information in effect at the time of printing. HolsetService reserves the right to make any changes at any time without obligation. If differences are found between yourturbocharger and the information in this manual, contact your local approved latest technology and the highest quality standards are used in the manufacture of Holset Turbochargers. Whenreplacement parts are needed, we recommend using only genuine Holset of ContentsIntroductionGeneral Information ..4 About the to Use the Manual ..4 Fault Finding Chart ..5 Symbols ..6 Component IdentificationTurbocharger Identification ..11 Components ..12 Exploded View ..13 Optional Components.

2 14 Component Disassembly and AssemblyService Tools ..15 Disassembly ..21 Assembly ..23 Installation Data ..30 Installation Checklist ..31 Table of ContentsPage 3 IntroductionGeneral InformationA turbocharger is a mechanical device which uses the engine s exhaust gases to force more air into the enginecylinders. A turbocharger uses energy from the engine to help increase its overall efficiency. Hot exhaust gas energy isused to turn a shaft and wheel . At the other end of the shaft is the compressor impeller (or compressor wheel),which draws in air and forces it into the engine increased air mass flow to the engine provides improved engine performance, lower exhaust smoke density,improved operating economy, altitude compensation, and noise reduction. The turbocharger has proven to be one of themost beneficial devices for improving engine performance. It performs its job very well, as long as it is properly cared the ManualThe procedures in this manual were developed to instruct in the correct overhaul of the Holset HX35/40 turbocharger toprovide for the optimum performance and minimum of maintenance to Use the ManualThis manual is organised according to the steps needed to most easily and correctly overhaul the Holset hx35 /40turbocharger.

3 In the unlikely event of turbocharger malfunction, please check the Fault Finding Chart to identify potentialcauses, before attempting disassembly. To make sure of optimum performance, certain items must be discarded duringthe disassembly operation and replaced with new for re-assembly. These items are indicated in the disassembly sectionwith the use of a * symbol. All items showing a * are available in a basic HX35/40 overhaul kit. Contact your local agentfor part number and turbocharger may have been manufactured using the core balance process and therefore MUST be checkbalanced on core balanced turbocharger will not have any co-relation marks on the thrust collar or oil slinger, and also may nothave co-relation marks on the end of the turbine shaft and impeller you intend to overhaul/repair a core balanced turbocharger, and do not have access to a core balancing machine,we recommend that you make your own rotor co-relation marks during disassembly ( see appropriate illustration in thedisassembly section) with an indelible-ink pen, so that these parts can be reassembled in the same relative refer to the balance data section of this manual for the balance limits to be used for either core balancing orrotor is important to note that operating a turbocharger with a Rotor or Core balance level greater than the published limitscould cause turbocharger or engine failure.

4 If you are in any doubt regarding the balancing process, please contact anapproved Holset distributor for InformationPage 4 IntroductionFault Finding Chart Engine Lacks Power Black Exhaust Smoke Blue Exhaust Smoke High Oil Consumption Turbocharger NoisyEngine Running HotPoor Transient ResponseSmokeCyclic Sound from the Turbocharger Oil Leak from Compressor Seal Oil Leak from Turbine SealDirty air cleanerClean or replace element according to manufacturer s recommendationsRestricted compressor intake ductRemove restriction or replace damaged parts as requiredRestricted air duct from compressor to intake manifoldRemove restriction or replace damaged parts as requiredRestricted intake manifoldRefer to engine manufacturer s manual and remove restrictionAir leak in feed from air cleaner to compressorReplace seals, gaskets or tighten fasteners as requiredAir leak in feed from compressor to intake manifoldReplace seals, gaskets or tighten fasteners as requiredAir leak between intake manifold and engineRefer to engine manufacturer s manual and replace gaskets or tighten fasteners as requiredForeign object in exhaust manifold (from engine)

5 Refer to engine manufacturer s manual and remove obstructionRestricted exhaust systemRemove restriction or replace damaged parts as requiredExhaust manifold cracked, gaskets blown or missingRefer to engine manufacturer s manual and replace gaskets or damaged parts as requiredGas leak at turbine inlet/exhaust manifold jointReplace gasket or tighten fasteners as requiredGas leak in ducting after turbine outletRefer to engine manufacturer s manual and repair leakRestricted turbocharger oil drain lineRemove restriction or replace damaged parts as requiredRestricted engine crankcase breatherRefer to engine manufacturer s manual, clear restrictionTurbocharger bearing housing sludged or cokedChange engine oil and oil filter, overhaul or replace turbocharger as requiredFuel injection pump or fuel injectors incorrectly setRefer to engine manufacturer s manual and replace or adjust faulty components as requiredEngine valve timing incorrectRefer to engine manufacturer s manual for correct settings and adjust as requiredWorn engine piston rings or linersRefer to engine manufacturer s manual and repair as requiredBurnt valves and/or pistonsRefer to engine manufacturer s manual and repair as requiredExcessive dirt build up on compressor wheel and/or diffuser vanesClean in accordance with details in the appropriate Holset publicationTurbocharger damagedFind and correct cause of failure.

6 Repair or replace turbocharger as necessaryFailed diaphragmReplace using correct actuator Service KitSiezed valveFree valve/replace complete turbine housing sub-assemblyLeaking hoseReplace hose and clipsWastegate mechanism set incorrectlyContact approved agent for correct setting detailsFault Finding ChartPage 5 IntroductionSymbols - EnglishThe following group of symbols have been used in this manual to help communicate the intent of the instructions. Whenone of the symbols appears, it conveys the meaning defined Serious personal injury or extensive property damage can result if the warning instructions arenot Minor personal injury can result or a part, an assembly or the engine can be damaged if thecaution instructions are not a REMOVAL or an INSTALLATION or part or mechanical or time part or that a WRENCH or TOOL SIZE will be a specific that the BALANCE MARKSon the rotor assembly are in alignmentPERFORMan electrical to another location in this manual or another publication for additional wear protective clothing at all 6 IntroductionSymbolsPage 7 IntroductionSimbolos - Espa olLos simbolos siguientes son usados en estes manual para clarificar el proceso de las instrucciones.

7 Cuado apareceuno de estos simbolos, su significado se espcifica en la parte Serios da os personales o da o a la propiedad puede resultar si las instrucciones deAdvertencia nose Da os menores pueden resultar, o de piezas del conjunto o el motor puede averiarse si lasinstrucciones de Precauci n nose un paso de REMOCIONo un paso de INSTALACIONo requiere pieza o el MEDICIONmec nica o del pieza o el que se dar una LLAVE DE TUERCASo el TAMA O DE un par torsor rese de que est n alineadas las MARCAS DE BALANCEen el MEDICIONel informaci n adicional refi rase a otro emplazamiento de este manual o a otra publicaci n de siempre llevar ropa 8 IntroductionSymbole - DeutschIn diesem Handbuch werden die folgenden Symbole verwendet, die wesentliche Funktionen hervorheben. Die Symbolehaben folgende Bedeutung:WARNUNG- Wird die Warnung nicht beachtet, dann besteht erh hte Unfall- und Besch Werden die Vorsichtsmassnahmen nicht beachtet, dann besteht Unfall- undBesch oder Baugruppe oder oder Baugruppe SSEwird vorgeschriebenes Drehmoment , da die AUSWUCHTMARKENan der Rotor-Baugruppe richtig ausgerichtet MESSUNG DURCHF Informationen an anderer Stelle bzw.

8 In anderen Handb mu immer getragen 9 IntroductionSymboles - Fran aisLes symboles suivants sont utilis s dans ce manuel pour aider communiquer le but des instructions. Quand l un deces symboles apparait, il voque le sens d fini ci-dessous:AVERTISSEMENT- De graves l sions corporelles ou des dommages mat rials consid rables peuventsuvenir si les instructions donn es sous les rubriques Avertissement nesont De petites l sions corporelles peuvent survenir, ou bien une pi ce, un ensemble ou le moteurpeuvent tre endommag s si les instructions donn es sous les rubriques Attention nesont curit pIndique une op ration de une op ration de INSPECTIONest n pi ce ou l MESURE m canique ou de pi ce ou l qu une DIMENSION DE CLEou D OUTIL sera donn un couple sp assurer que les REPERES D QUILIBRAGEsur l ensemble de rotor sont align MEASURE reporter un autre endroit dans ce manuel ou une autre publication pour obtenir des information pluscompl faut toujours mettre v tements de 10 IntroductionS mbolos - Portugu sOs s mbolos a seguir ser o utilizados neste manual para facilitar a comunica o das instru es e seue significadosest o d scritos O- Se as instru es n o forem seguidas, h possibilidade de ocorrer s rios danos pessoais Danos aos componentes, ao conjunto ou ao motor.

9 Ou mesmo pequenos danos pessoaispodem ocorrer se as instru es n o forem um passe de um passo de INSPE pe a ou MEDI Omec nica ou de pe a ou o necessidade de acordo com o de que as MARCAS DE BALANCEAMENTOdo conjunto eixorotor estejam medi o EL em outra se o deste manual ou em publica o par obter informa es adicionaisPor favor, sempre utilize EPI (Equipamento de Protecao Individual)Component IdentificationTurbocharger IdentificationA dataplate is fitted to the compressor housing (8). Theinformation on this dataplate must be quoted for service andparts IdentificationPage 11 Component Identification835 XXXXXH01 XXXXHX35HX30/35/40 - Center Housing Rotating Assembly ( )2 Components - HX35/40 Item Housing15 Turbine Housing16 Assembly Turbine Wheel17 Compressor Wheel18 Compressor Housing111 Journal Bearing112 Thrust Bearing113 Piston Ring Seal, Turbine116 Piston Ring Seal, Compressor122 Retaining Ring131 Oil Slinger132O Ring Seal, Bearing Housing133 Oil Baffle134 Inlet Baffle136 Thrust Collar138 Heat Shield143 Oil Seal Plate157 Bolt, Turbine Housing ( HX35/40 )661 Locknut, Compressor Wheel164 Ring Retaining Bearing (Snap Ring)466 Insert, Retaining Ring188 Clamp Plate, Turbine Housing ( HX35/40 )

10 291 Compressor Cover Retaining Ring1 Components - HX30/35/40 Page 12 Component Identification8916161**76643321631613381 1336411588361264457 Exploded View - HX30/35/40 Page 13 Component IdentificationExploded View - HX35/40 * Alternative optionsOld Style Nut3503562 New Style Nut3590306 Optional ComponentsCompressor Inlet Baffle (34) (if fitted)Where specified by the engine manufacturer, certainturbochargers can have a pressed steel baffle fitted into theinlet item is notserviceable and if damaged, mustbereplaced, as the geometry of the part is critical to theperformance of the Bearing Housing (4) (if fitted) As with the inlet baffle option, certain engine manufacturerscan specify a watercooled bearing housing. These canhave additional water feed and drain plug ComponentsPage 14 Component IdentificationCaution: Always use specified torque. Failure to doso may result in turbocharger / engine Compressor Wheel LocknutHolset have introduced a new compressor wheel lock nutwhich is to be fitted to all new WH1C/E turbochargers.