TSB150095-061215

New Turbocharger Turbine Housing Repair Kit
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Technical Service Bulletin Number
TSB150095
Technical Service Bulletin
Subject
New Turbocharger Turbine Housing Repair Kit
Warranty Statement
The information in this document has no effect on present warranty coverage or repair
practices, nor does it authorize TRP or Campaign actions.
Contents
Product Affected


ISX12 G CM2180 EJ
Description of Change
This document announces the release of new HE300WG turbocharger turbine housing repair
kits, Part Numbers 4034271 and 4034272.
Service Instructions
The new turbocharger turbine housing repair kits, Part Number 4034271 or 4034272, are to be
used to replace the existing turbocharger turbine housing if the turbocharger housing does not
pass the inspection criteria or for the following conditions:








Turbocharger turbine intake temperature sensor seized
Turbocharger wastegate seized
Damaged turbocharger wastegate actuator
Broken capscrews
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Inlet flange does not meet reuse guidelines
NOTE: The turbine housing kit is not to be used for Grade 1 or 2 cracked turbine
housings. A cracked turbine housing with no signs of turbine wheel rubbing is not a
malfunctioning turbocharger and does not require replacement.
See the HE300WG Turbocharger Turbine Housing Reuse Guidelines, Bulletin 4367442.
See the ISX12 G CM2180 EJ Service Manual, Bulletin 4310682, for inspection criteria and
turbine housing removal and installation procedures. Refer to Procedure 010-033 in section
10.
Part Identification
Figure 1, Turbocharger Data Plate
1. Turbocharger Assembly Number - This is used on QuickServe® Online to determine
turbocharger kit number.
2. Turbocharger Serial Number
3. Turbocharger Part Number - This will be the kit number on a replacement turbocharger
4. Model Number
Service Parts Availability
See Figure 1 above for associated number locations in Table 1 below.
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Table 1, Service Parts
Assembly
Number
Option
(Figure 1, Item Number
1)
Original
Turbocharger Part
Number (Figure 1,
Item 3)
Replacement
Turbocharger Kit Part
Number (Figure 1,
Item 3)
New Turbine
Housing
Repair Kit Part
Number
3788265
PP20166
(Mid
Mount)
3788266
4352254*
4034271
3787965
PP20167
(Low
Mount)
3787966
4352139*
4034272
*NX Recon Equivalent Available
Table 2, Turbocharger Turbine Housing Repair Kit, Part Number 4034271
Part Number
Description
Quantity
2840781
Screw, hexagon head set
6
2839879
Plate, clamping
2
3786294
Kit, turbocharger gasket
1
5324845
Housing, turbine (with preset wastegate)
1
Table 3, Turbocharger Turbine Housing Repair Kit, Part Number 4034272
Part Number
Description
Quantity
2840781
Screw, hexagon head set
6
2839879
Plate, clamping
2
3786294
Kit, turbocharger gasket
1
5324846
Housing, turbine (with preset wastegate)
1
Publications Affected
See the ISX12 G CM2180 EJ Service Manual, Bulletin 4310682. Refer to Procedure 010-033
in section 10.
See the ISX12 G CM2180 EJ Service Manual, Bulletin 4310682. Refer to Procedure 010-050
in Section 10.
See the HE300WG Turbocharger Turbine Housing Reuse Guidelines, Bulletin 4367442
Document History
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New Turbocharger Turbine Housing Repair Kit
Date
2015-6-12
Page 4 of 4
Details
Module Created
Last Modified: 23-Jun-2015
Copyright © 2000-2010 Cummins Inc. All rights reserved.
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010-033 Turbocharger
General Information
NOTE: Only those steps required for the
specific repair need to be completed.
Cleaning and compressor section removal
is not required for replacement of the
turbine housing.
NOTE: Before disassembly, check for
turbine and compressor blade damage.
Measure the bearing radial movement and
axial clearance to be sure that the bearing
housing is within the MIN/MAX limits.
Turbine Housing Kit
The Turbocharger Turbine Housing Repair Kit
should be used to replace the existing turbine
housing if the housing does not pass the
inpsection criteria or for the following
conditions:










Turbine intake temperature sensor
seized
Wastegate siezed
Damaged wastegate actuator
Broken capscrews
Inlet flange damage.
Initial Check
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Remove the intake pipe from the
turbocharger. See the Remove section in
this procedure.
Inspect the turbocharger compressor
impeller blades for damage.
Replace the turbocharger if damage is
found. See the Remove and Install
sections in this procedure.
If the compressor impeller is damaged,
inspect the intake piping and filter element
for damage.
Repair any damage before operating the
engine.
Remove the exhaust pipe from the
turbocharger. See the Remove section in
this procedure.
Inspect the turbine wheel for damage.
Replace the turbocharger if damage to the
turbine wheel is found. See the Remove
and Install sections in this procedure.
Inspect the turbine housing and wastegate
valve seat for white deposits. White
deposits in the turbine housing and
wastegate valve seat may indicate an
exhaust gas recirculation (EGR) cooler
leak. An EGR cooler leak that occurs for a
prolonged period of time may cause the
turbocharger wastegate valve to bind or
seize.
If white deposits are found, pressure test
the EGR cooler. Refer to Procedure 011019 in Section 11.
If the EGR cooler passes the pressure
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test, perform a cooling system Leak Test.
Refer to Procedure 008-020 in Section 8.
NOTE: Red or pink deposits are normal
and do not indicate that the EGR cooler
needs to be tested.
Axial Clearance Check










NOTE: The axial clearance check
can be performed with the
turbocharger mounted on the
engine.
Secure the turbine housing and
check the axial clearance using dial
depth gauge, Part Number ST537.
Push the rotor assembly away from
the gauge.
Set the gauge to zero.
Push the rotor assembly toward the
gauge and record the reading.
Rotor Assembly Axial Clearance
mm
0.127
0.025
in
MAX
MIN
0.005
0.001
If the axial clearance does not meet the
specification, the turbocharger must be
replaced. Go to the Remove and Install
sections in this procedure.
Radial Clearance Check




NOTE: The radial clearance check
can be performed with the
turbocharger mounted on the
engine.
Secure the turbine housing and
check the radial clearance using dial
depth gauge, Part Number ST537,
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configured to measure radial
distance.
Push the rotor assembly away from
the gauge.
Set the gauge to zero.
Push the rotor assembly toward the
gauge and record the reading.
Rotor Assembly Radial Clearance
mm
0.508
0.330
in
MAX
MIN
0.020
0.013
If the radial clearance does not meet the
specification, the turbocharger must be
replaced. Go to the Remove and Install
sections in this procedure.
Lubricating Oil Leak Check




Inspect the turbocharger compressor
intake and discharge for oil.
If oil is present in the compressor
intake as well as in the discharge,
check upstream in the turbocharger
for the source of the oil.
If oil is present only in the discharge side,
install the air intake and charge-air cooler
piping. See equipment manufacturer
service information.
Check for intake restriction. Refer to
Procedure 010-031 in Section 10.
NOTE: If the engine experiences a
turbocharger malfunction or any other
occasion where oil is put into the
charge-air system, the charge-air
system must be inspected and cleaned.
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Refer to Procedure 010-027 in Section
10.
NOTE: If the engine experiences a
turbocharger malfunction that results
in coolant or oil entering the intake, the
charge-air cooler system as well as the
fuel control housing must be inspected
and cleaned. Use the following
procedure for the charge-air cooler.
Refer to Procedure 010-027 in Section
10. Use the following procedure for the
fuel control housing. Refer to
Procedure 005-009 in Section 5.
NOTE: If the engine experiences a
turbocharger malfunction or any other
occasion where oil is put into the
exhaust, the aftertreatment
components must be inspected.
Inspect the exhaust catalyst. Refer to
Procedure 011-078 in Section 11.
Fluorescent Dye Tracer
Add one unit of fluorescent tracer, Part
Number 3376891, to each 38 liters [10 gal]
of engine lubricating oil.
Operate the engine at low idle for 10
minutes.
Shut the engine OFF.
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Allow the turbocharger to cool.
Remove the exhaust pipe from the turbine
housing. See the Remove Section in this
procedure.
Use a high-intensity black light, Part
Number 2892320, to inspect the turbine
outlet for leaks.
A yellow glow indicates an oil leak.
If oil is found in the turbine housing,
remove the oil drain line and check for
restrictions. Refer to Procedure 010-045 in
Section 10.
Clear any restrictions found.
If these checks do not reveal the problem,
remove the turbocharger. See the Remove
and Install sections in this procedure.
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Use a high-intensity black light, Part
Number 2892320, to inspect the turbine
inlet for leaks.
A yellow glow indicates an oil leak from
the engine.
If a yellow glow is not seen in the turbine
inlet, replace the turbocharger. See the
Remove and Install sections in this
procedure.
Install the exhaust pipe onto the
turbocharger turbine outlet and tighten the
clamp. See the Install section in this
procedure.
Install the intake pipe onto the
turbocharger compressor inlet and tighten
the clamp. See the Install section in this
procedure.
Leak Test
WARNING
Do not remove the pressure cap from a
hot engine. Wait until the coolant
temperature is below 50°C [120°F]
before removing the pressure cap.
Heated coolant spray or steam can
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cause personal injury.
WARNING
Coolant is toxic. Keep away from
children and pets. If not reused,
dispose of in accordance with local
environmental regulations.
This test only needs to be performed if
troubleshooting for coolant loss, or if a
leak is suspected.
If a turbocharger internal coolant leak is
suspected, use the Turbocharger Coolant
Leak Test Kit, Part Number 5299836,
along with Air Pressure Regulator Kit, Part
Number 3164231, to check for a leak.










Drain the cooling system. Refer to
Procedure 008-018 in Section 8.
To test for a turbocharger bearing
housing internal coolant leak,
disconnect the coolant inlet line from
the turbocharger bearing housing
adapter and install the 14mm o-ring
to Joint Industry Council (JIC)
adapter fitting for the pressure
regulator supplied in the
Turbocharger Coolant Leak Test Kit,
Cummins® Part Number 5299836.
Remove the coolant return line and
install a 14mm plug into the bearing
housing adapter.
If equipped, remove the coolant
reservoir line and install a 14mm plug
into the bearing housing adapter.
Use compressed air supply to
pressurize the turbocharger to 276
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kPa [40 psi].
Close the air pressure regulator.
Watch for the pressure to decrease.
The pressure must not decrease
more than 34 kPa [5 psi] in 1 minute.
If the pressure decreases, use a
spray bottle of soapy water to wet all
of the hose connections. Bubbles will
appear if the connections are
leaking.
Correct any leaking fittings and test
again.
If the pressure decreases more than
34 kPa [5 psi] in one minute and the
hose connections are not leaking,
replace the turbocharger.
If the pressure does not decrease,
no leaks have been detected in the
turbocharger bearing housing. No
further Turbocharger Coolant Leak
Test steps are necessary.
NOTE: For access, the turbocharger
compressor outlet connection may
need to be removed. See equipment
manufacturer service information.


Install the coolant inlet and outlet
line, coolant reservoir line, and all
fittings. Inspect for coolant leaks
during operation after final assembly
Preparatory Steps
WARNING
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Batteries can emit explosive gases. To
reduce the possibility of personal injury,
always ventilate the compartment
before servicing the batteries. To
reduce the possibility of arcing, remove
the negative (-) battery cable first and
attach the negative (-) battery cable
last.
WARNING
Do not remove the pressure cap from a
hot engine. Wait until the coolant
temperature is below 50°C [120°F]
before removing the pressure cap.
Heated coolant spray or steam can
cause personal injury.
WARNING
Coolant is toxic. Keep away from
children and pets. If not reused,
dispose of in accordance with local
environmental regulations.
WARNING
Some state and federal agencies have
determined that used engine oil can be
carcinogenic and cause reproductive
toxicity. Avoid inhalation ofvapors,
ingestion, and prolonged contact with
used engine oil. If notreused, dispose of
in accordance with local environmental
regulations.
NOTE: Brush away all loose dirt from
the around the area of the air handling
connections to avoid contamination of
the interior of the engine.
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NOTE: For front out exhaust
configurations, the turbocharger will
need to be removed with both coolant
return and oil supply lines installed to
the bearing housing.
NOTE: Take note of oil and coolant line
orientation prior to removal and install
in the same manner. Do not lift the
turbocharger by the coolant return
lines.




















Disconnect the batteries. See
equipment manufacturer service
information.
Drain the cooling system. Refer to
Procedure 008-018 in Section 8.
Disconnect the air crossover tube.
Refer to Procedure 010-019 in
Section 10.
Remove the turbocharger outlet
connection. Refer to Procedure 010132 in Section 10.
Remove the oil supply line from the
turbocharger. Refer to Procedure
010-046 in Section 10.
Remove the oil drain line from the
turbocharger. Refer to Procedure
010-045 in Section 10.
Remove the turbocharger coolant
lines. Refer to Procedure 010-041 in
Section 10.
Disconnect the turbocharger actuator
air supply line. Refer to Procedure
010-050 in Section 10.
Disconnect the turbocharger
compressor intake pressure sensor.
Refer to Procedure 019-433 in
Section 19.
Disconnect the turbocharger
compressor intake
humidity/pressure/temperature
sensor. Refer to Procedure 019-509
in Section 19.
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Remove
Remove the exhaust piping.
Remove the turbocharger compressor air
inlet pipe.
Remove the four turbocharger mounting
nuts.
Remove the turbocharger and gasket.
Disassemble
WARNING
To reduce the possibility of personal
injury, wear goggles and protective
clothing.
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Use the following steps to separate the
turbocharger turbine housing from the
bearing housing.
If the turbine housing will be used again,
scribe a mark on the turbine housing and
bearing housing to aid alignment during
assembly.
If the turbine housing is being replaced,
create an alignment mark that can be used
to align the bearing housing with the new
turbine housing.
Secure the turbine housing flange in a vice
or fixture that will not damage the sealing
surface of the flange.
Seized capscrews may be freed by
spraying them with penetrating oil and
soaking for 20 minutes, or the period of
time recommended by the oil
manufacturer.
Do not shear the turbine housing clamp
plate capscrews.
NOTE: It may be necessary to rotate the
turbine housing once all capscrews are
loosened in order to have clearance to
remove all the capscrews.
Loosen and remove the capscrews and
clamp plates.
CAUTION
Never direct hammer blows onto the
turbine housing flange.
CAUTION
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Use care when separating the bearing
housing from the turbine housing. The
turbine blades can be damaged when
the turbine housing is removed.
CAUTION
Some turbine housings are pinned to
the bearing housing. Use care to not
bend the locating pin during
disassembly.
Use a soft hammer to tap the turbine
housing down against a soft bench
surface. When the bearing housing
loosens, remove it from the turbine
housing.
NOTE: Unless the wastegate actuator
or the turbine housing are to be
replaced, leave the turbine housing,
bracket, and actuator as an assembly
while servicing the turbocharger. Never
adjust the end link of an assembled
wastegate turbocharger. End links are
set to precise limits to maintain
emissions and performance
specifications.
If required, remove the turbocharger
wastegate actuator from the turbine
housing. Refer to Procedure 010-050 in
Section 10.
Use the following steps to separate the
turbocharger compressor housing from the
bearing housing.
Place the compressor inlet on a clean flat
surface.
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Scribe a mark on the compressor housing,
retaining ring, and bearing housing to aid
alignment during assembly.
WARNING
To reduce the possibility of personal
injury, wear goggles and protective
clothing.
Remove the compressor cover retaining
ring using circlip pliers, Part Number
3575186.
If the circlip is seized in its groove, gently
tap one end with a leather hammer and
drift.
CAUTION
Use care when separating the bearing
housing from the compressor housing.
The compressor blades can be
damaged when the compressor
housing is removed.
CAUTION
Some compressor housings are pinned
to the bearing housing. Use care to not
bend the locating pin during
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disassembly.
Secure the turbine housing flange in a vice
or fixture that will not damage the sealing
surface of the flange, or be sure that the
turbocharger is stable on a work bench.
Use a soft hammer to tap the compressor
housing off the bearing housing.
On some models, removal of the
compressor housing will expose an o-ring
seal. The seal must be removed and
discarded.
The inlet baffle must be removed to clean the
compressor housing.
The illustration shows an old style inlet baffle
(A) and a new style inlet baffle (B).
The new style baffle (B) has been improved
and no longer incorporates four stepped
areas. This gives the new baffle an increased
service life.
CAUTION
When removing the inlet baffle retaining
ring, be careful not to damage the
compressor wheel with the screwdriver.
Use a clean shop towel or rubber bung
to protect the compressor wheel.
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Use a flat screw driver to carefully apply
force in the area shown (C). As the
retaining ring starts to move, force the
screwdriver under the ring as shown in
(D).
Push the screwdriver in a
counterclockwise direction to force the
retaining ring out of its groove.
Remove the retaining ring.
Remove the inlet baffle.
Clean and Inspect for Reuse
Use the following for additional turbine
housing reuse guidelines. Refer to
HE300WG Turbocharger Turbine Housing
Reuse Guidelines, Bulletin 4367442.
Inspect the parts prior to cleaning to detect
signs of burning and other conditions to
obtain as much information as possible.
Always remove the wastegate actuator
before cleaning.
The housing surfaces adjacent to the
turbine and compressor wheels must be
clean, smooth, and free from deposits.
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WARNING
When using solvents, acids, or alkaline
materials for cleaning, follow the
manufacturer’s recommendations for
use. Wear goggles and protective
clothing to reduce the possibility of
personal injury.
Soak the housings in a non-corrosive, low
flash point metal cleaner to loosen any
deposits.
WARNING
Wear appropriate eye and face protection
when using compressed air. Flying debris
and dirt can cause personal injury.
Dry the components with compressed air.
Scale-like deposits, if any, must be
removed by using a non-metallic bristle
brush.
After removing any deposits, clean and dry
the components again.
WARNING
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Wear appropriate eye and face
protection when using compressed air.
Flying debris and dirt can cause
personal injury.
CAUTION
Do not direct bead spray onto the
wastegate valve spindle. The beads
can penetrate the spindle bore and lead
to spindle seizure.
CAUTION
Do not bead blast aluminum and cast
iron components together.
It is permissible to bead blast the turbine
housing if chemical and brush cleaning is
not effective.
After removing any deposits, clean and dry
the components again.
Clean the turbocharger and exhaust
manifold gasket surfaces.
Inspect the turbocharger and exhaust
manifold gasket surfaces and the
mounting studs for cracks or other
damage.
Cracked Turbine Housing Grading
Scale:


There are four grades for the reuse
turbocharger guidelines.
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Grade 1


Crack at the tongue or at the
wastegate port visible from turbine
inlet.
Sometimes the crack is visible from turbine
outlet depending on whether or not the
wastegate flap is opened for inspection.
NOTE: Do not replace the turbocharger or
turbine housing for a Grade 1 crack.
Grade 2


The crack that has progressed from
the tongue and into the turbine
profile, but no wheel rub has
occurred.
NOTE: Do not replace the turbocharger
or turbine housing for a Grade 2 crack.
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Grade 3


The turbine housing is cracked and
distortion has allowed the turbine
wheel to rub the housing.
NOTE: Replace the turbocharger for a
Grade 3 crack.
External


These cracks allow exhaust gases to
leak to the atmosphere.
NOTE: Replace the turbocharger if
external cracks are found.
NOTE: Replace the turbocharger if
external cracks are found.
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If the turbine housing is cracked and
allows leakage to the atmosphere, the
turbine housing must be replaced.
Cracking of the internal wall at the entry to
the turbine wheel (tongue) is an
acceptable service condition and the
turbine housing can be used again.
Radial cracks can occur around the
wastegate valve seat.
This type of cracking does not affect the
performance of the turbocharger. Do not
replace the turbine housing or
turbocharger for cracks around the
wastegate valve seat.
Unacceptable cracking of the turbine
housing inlet flange may require turbine
housing replacement. Acceptance and
rejection guidelines are shown in the
illustration.
Acceptable exhaust manifold and turbine
housing cracks:






Must be 10 mm [0.39 in] or less in
length
Must be separated from each other
by no less than 10 mm [0.39 in]
Must not extend to the edge of the
flange.
Acceptable exhaust manifold and turbine
housing flange scaling:
Must be less than 0.1 mm [0.004 in] or
less in depth.
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Measure the exhaust manifold outlet and
turbine housing inlet flange flatness.
Inlet Flange Flatness Specification
mm
0.1
in
MAX
0.004
If the mounting surface is out of
specification, the turbocharger must be
replaced.
Verify that the fastener hole diameter is not
more than 1.5 mm [0.059 in] larger than
the maximum thread diameter of the
fastener.
Check flange threaded holes with an M10
x 1.5 thread gauge.
Wastegate Movement Check






To check the wastegate valve shaft
condition, disconnect the actuator
from the crank pin and move the
wastegate valve by hand.
If binding or seizure is observed,
replace only the turbine housing with
a turbine housing kit.
The wastegate crank pin can be
worn by partial seizure of the valve
mechanism. Scoring may be caused
by severe local environmental
conditions.
Partial seizure of the valve mechanism and
environmental conditions can also lead to
elongation of the rod end bore which
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locates on the crank pin. This elongation
must not exceed 0.50 mm [0.020 in].
Test the turbocharger wastegate actuator
for proper operation and replace, if
necessary. Refer to Procedure 010-050 in
Section 10.
Inspect the internal profile of the
compressor housing for scoring damage
due to possible contact with the
compressor wheel.
Check that the compressor housing
retaining ring groove is free from deposits
and is not worn.
Replace the compressor housing if profile
damage is visible.
Good groove and abutment face condition
are critical to the integrity of the
compressor housing to bearing housing
joint.
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Assemble
If removed, install the wastegate actuator.
Refer to Procedure 010-050 in Section 10.
NOTE: If installing a new turbine
housing, do not remove or adjust the
wastegate actuator assembly. The
acutator is calibrated at the factory.
CAUTION
Use care when assembling the bearing
housing to the turbine housing. The
turbine blades can be damaged when
the turbine housing is installed.
CAUTION
Some turbine housings are pinned to
the bearing housing. Use care to not
bend the locating pin during
disassembly.
Use the following steps to assemble the
bearing/compressor housing assembly
onto the turbine housing.
Secure the turbine housing flange in a vice
or fixture that will not damage the sealing
surface of the flange.
Apply a high temperature anti-seize
compound to the bearing housing locating
bore of the turbine housing.
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Slide the bearing and compressor housing
assembly into the turbine housing.
NOTE: Install the clamp plates and
loosly tighten capscrews before
attempting to align the marks created
during disassembly, since rotation of
the housings may be necessary in
order to install all capscrews.
Align the scribe marks created during
disassembly, or locate the assembly onto
the locating pin, if equipped.
Install the clamp plates and capscrews.
Depending on housing orientation, some
clamp plate capscrews have restricted
access. In these cases, use a suitable
torque wrench adapter attached to a
specially calibrated torque wrench.
Tighten the capscrews.
Torque Value: 26 n.m [230 in-lb]
If available torque wrench and adapters do
not allow access to properly torque a
capscrew, torque all capscrews with
sufficient tool clearance prior to performing
the following steps:
NOTE: Perform the following steps only
if there is not sufficient tool clearance.
1. Tighten capscrew until fully seated.
2. Rotate an additional 60 degrees.
Turn the compressor wheel by hand to be
sure it rotates freely.
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Use the following steps to assemble the
compressor housing.
Install the inlet baffle into the compressor
housing inlet.
WARNING
To reduce the possibility of personal
injury, wear goggles and protective
clothing.
Install the retaining ring into the
compressor housing inlet.
Hold one end of the retaining ring in the
groove and press the remainder of the
retaining ring into position.
Use a flat screwdriver to be sure that the
retaining ring is correctly seated in the
groove.
If the turbocharger bearing housing was
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equipped with an o-ring, a new o-ring
must be installed.
Use clean engine oil to lubricate the new
o-ring.
Install the o-ring on the bearing housing.
CAUTION
Use care when installing the
bearing/turbine housing onto the
compressor housing. The compressor
blades can be damaged when the
compressor housing is installed.
CAUTION
Some compressor housings are pinned
to the bearing housing. Use care to not
bend the locating pin during assembly.
Make sure that the turbocharger
compressor housing is stable on a work
bench with the air inlet facing downward.
Place the retaining ring onto the bearing
housing with the chamfered face upward,
away from the compressor housing.
Align the scribe marks on the housings
and retaining ring that were created during
disassembly or locate the assembly onto
the locating pin, if equipped.
Install the assembly onto the compressor
housing, taking care not to trap the o-ring.
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WARNING
To reduce the possibility of personal
injury, wear goggles and protective
clothing.
Use circlip pliers, Part Number 3575186,
to install the retaining ring.
CAUTION
Use care to not damage the bearing
housing with the drift.
Lightly tap the ends of the retaining ring
with a hammer and drift to make sure the
ring is properly located in its groove.
Turn the compressor wheel by hand to be
sure it rotates freely.
Install
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WARNING
This component or assembly weighs
greater than 25 kg [50 lb]. To prevent
serious personal injury, be sure to have
assistance or use appropriate lifting
equipment to lift the component or
assembly.
NOTE: On engines incorporating the
low-mount turbocharger option, install
the coolant supply line onto the
turbocharger, prior to installation of the
turbocharger onto the engine. Make
sure the coolant supply line does not
contact the turbocharger assembly or
other engine components when
installed. Refer to Procedure 010-041 in
Section 10.
Apply a film of high-temperature anti-seize
compound to the turbocharger mounting
studs.
Install a new gasket and install the
turbocharger.
Install and tighten the four mounting nuts.
NOTE: The torque values have been
established with anti-seize compound
as a lubricant.
Torque Value: 60 n.m [44 ft-lb]
If installing a new turbocharger, it can be
necessary to rotate the turbocharger
compressor housing to properly align with the
charge-air cooler piping.
Rotate the turbocharger compressor housing
by loosening the compressor cover retaining
ring using circlip pliers, Part Number
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3575186.
If the circlip is seized in its groove, gently tap
one end with a leather hammer and drift.
Rotate the turbocharger compressor housing
to properly align with the charge-air cooler
piping.
Lightly tap the ends of the retaining ring with a
hammer and drift to make sure the ring is
properly located in its groove.
Turn the compressor wheel by hand to be
sure it rotates freely.
Install the intake pipe onto the
turbocharger compressor inlet and tighten
the clamp.
Torque Value: 8 n.m [71 in-lb]
Install the exhaust pipe to the turbocharger
turbine outlet and tighten the clamp.
Torque Value: 8 n.m [71 in-lb]
Install the exhaust pipe onto the
turbocharger turbine outlet.
Install the V-band clamp, observing the
correct orientation as shown.
NOTE: The clamp bolt must be oriented
so that the threads are pointed in the
direction of the wastegate actuator and
the band must be rotated such that it
does not interfere with the wastegate
actuator rod when the rod is extended.
If the orientation of the V-band is not
correct, damage can result to the
turbocharger wastegate actuator.
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Tighten the V-band clamp.
Torque Value: 8 n.m [71 in-lb]
Prime
Install the turbocharger oil drain line. Refer
to Procedure 010-045 in Section 10.
Lubricate the bearings by pouring 59 to 89
ml [2 to 3 oz] of clean 15W-40 engine oil
into the turbocharger oil supply line fitting.
Rotate the turbine wheel to allow the oil to
enter the bearing housing.
NOTE: If too much oil is poured into the
bearing housing, the oil may leak past
the seals. This is not regarded as a
malfunction, since the seals are not
dynamic and rely on exhaust gas and
boost pressure to provide a proper
seal.
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Finishing Steps
WARNING
Batteries can emit explosive gases. To
reduce the possibility of personal injury,
always ventilate the compartment
before servicing the batteries. To
reduce the possibility of arcing, remove
the negative (-) battery cable first and
attach the negative (-) battery cable
last.




















Install the turbocharger oil supply
line. Refer to Procedure 010-046 in
Section 10.
Connect the turbocharger coolant
lines. Refer to Procedure 010-041 in
Section 10.
Connect the turbocharger actuator
air supply line. Refer to Procedure
010-050 in Section 10.
Install the turbocharger compressor
outlet connection. Refer to
Procedure 010-132 in Section 10.
Connect the air crossover tube.
Refer to Procedure 010-019 in
Section 10.
Connect the turbocharger
compressor pressure sensor. Refer
to Procedure 019-433 in Section 19.
Connect the turbocharger
compressor intake
humidity/pressure/temperature
sensor. Refer to Procedure 019-509
in Section 19.
Fill the cooling system. Refer to
Procedure 008-018 in Section 8.
Connect the battery. See equipment
manufacturer service information.
Start and operate the engine and
check for leaks.
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Last Modified: 06-Jul-2015
Copyright © 2000-2010 Cummins Inc. All rights reserved.
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Turbocharger Wastegate Actuator
Page 1 of 8
010-050 Turbocharger Wastegate Actuator
Initial Check
CAUTION
All wastegates come precalibrated and can
not be adjusted in the field. Attempts to
adjust the wastegate can result in engine
damage.
The wastegate control line takes boost from
the turbocharger wastegate control valve to
the wastegate capsule.
Inspect the wastegate control line for
cracks or holes.
Remove the boost reference line from the
air intake connection and apply 103 kPa
[15 psi] to the line. This will also pressurize
the boost reference line from the low
pressure regulator housing to the
wastegate actuator.
Check for leaks by spraying all lines and
fittings with a mixture of mild soap and
water. Repair leaking fittings or lines.
Replace the line if it is damaged.
NOTE: The electronic wastegate control
valve is a normally closed valve.
However, at supply pressures greater
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than 103 kPa [15 psi], the valve may be
lifted and some leakage observed. If the
wastegate control valve leaks at 103
kPa [15 psi] or less, replace the
wastegate control valve.
Inspect the wastegate mounting bracket,
actuator rod, and lever for damage. A bent
wastegate mounting bracket, actuator rod,
or lever can cause improper operation.
If the wastegate mounting bracket,
actuator rod, or lever is bent, it must be
replaced.
Test
In some applications the turbocharger
must be removed to test the wastegate
actuator. Refer to Procedure 010-033 in
Section 10.
Disconnect the wastegate control line from
the wastegate capsule.
Attach a dial indicator (1) as shown, so
that its shaft is in line with the wastegate
actuator rod. Set the indicator to zero.
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Connect clean, regulated air pressure and
a pressure gauge to the capsule. Apply
200 kPa [29 psi] to make sure the
wastegate is functioning properly.
The rod must move approximately 12.7
mm [0.500 in] without any sticking or air
leakage.
Air must not be heard, such as air leaking
through a functional wastegate capsule.
A small amount of travel when air pressure
is first applied is normal. The tolerance is
being removed from the system.
If no movement of the actuator rod is
detected, detach the actuator control rod
from the wastegate lever pin.
Actuate the lever by hand to be sure that
the shaft rotates freely and is not seized.
If the wastegate lever can not be moved
by hand, inspect the turbocharger turbine
housing for coolant deposits. Use the
following procedure to perform the Initial
Checks. Refer to Procedure 010-033 in
Section 10.
Replace the turbine housing. Refer to
Procedure 010-033 in Section 10.
If the wastegate lever moves freely by
hand, replace the turbocharger wastegate
actuator.
Remove
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In some applications the turbocharger
must be removed in order to remove the
wastegate actuator. Refer to Procedure
010-033 in Section 10.
Prior to removal, note the position and the
length of the control rod from the boost
capsule housing and the orientation of the
boost capsule hose connector in relation to
the mounting bracket.
Remove the retaining clip from the control
lever.
Remove the wastegate control line from
the wastegate capsule.
CAUTION
Be careful not to bend the control lever.
Engine damage can result.
Remove the boost capsule actuator rod
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end from the turbocharger wastegate
lever. This can be accomplished by slowly
applying regulated air pressure to the
boost capsule until the control rod is
activated.
Remove the control rod from the
turbocharger wastegate lever pin.
If the boost capsule diaphragm material is
ruptured and will not hold air pressure,
manually pull the control rod outward in
order to overcome boost capsule spring
tension for removal of the control rod from
the turbocharger wastegate lever pin.
Loosen the boost capsule mounting
capscrews, disconnect the air supply
hose, and remove the assembly from the
mounting bracket.
Clean and Inspect for Reuse
Inspect the wastegate control line for
cracks or holes. Replace the line if it is
damaged.
Inspect the wastegate mounting bracket,
actuator rod, and lever for damage. A bent
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wastegate mounting bracket, actuator rod,
or lever can cause improper operation.
If the wastegate mounting bracket,
actuator rod, or lever is bent, it must be
replaced.
If the actuator bracket is removed from the
turbocharger turbine housing, the actuator
preload will be shifted out of calibration.
Install a new factory preset turbocharger
actuator kit.
Install
Install the end-link over the turbocharger
wastegate lever pin. With the spine of the
spacer visible and the turbocharger
wastegate lever pushed toward the rod,
lay the actuator alongside the mounting
bracket.
NOTE: Do not install the two studs into
the mounting holes at this time.
Adjust the length of the actuator assembly
by removing it from the turbocharger,
rotating the end-link, and installing the
actuator until the underside of the actuator
will just fit over the bracket mounting studs
with less than 0.5 mm [0.020 in] gap.
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The setting is correct when the underside of
the actuator will just fit over the bracket with
less than 0.5 mm [0.020 in] gap.
Install the actuator mounting studs into the
holes in the bracket.
Install the end-link onto the crank pin.
Install the control rod retaining clip.
Tighten the mounting nuts to the proper
torque specification.
Torque Value: 8 n.m [71 in-lb]
Tighten the control rod jam nut against the
end-link. Cut the tie wrap and remove the
tie wrap and spacer piece. Discard the tie
wrap. Contine turning the jam nut in the
same direction, and tighten against the
end-link.
Torque Value: 8 n.m [71 in-lb]
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Install the wastegate control line to the
actuator using the new hose clamp
provided.
Last Modified: 17-Jun-2015
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HE300WG Turbocharger Turbine Housing Reuse Guidelines
Service Bulletin Number
4367442
Page 1 of 14
Date
16-JUL-2014
Service Bulletin
HE300WG Turbocharger Turbine Housing Reuse
Guidelines
General Information






This bulletin applies to ISL G CM2180 and ISX12 G CM2180 EJ HE300WG
turbochargers. The grading scale and reuse guidelines should be followed to reduce
unnecessary repairs.
ISL G Turbocharger Turbine Housing Repair Kit, Part Number 5322762.
An ISX12 G turbine housing that does not meet reuse guidelines would require a
turbocharger replacement.
Turbocharger Turbine Housing Feature Identification
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Volute (1), Tongue (2)
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Inlet Flange (1), Volute (2)
Wastegate Valve (1), Wastegate Port (2)
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Profile (1)
The following are the four grading scales and reuse guidelines for a cracked turbine housing.
HE300WG Cracked Turbine Housing Grading Scale








Grade 1: Crack at the tongue or at the wastegate port visible from turbine inlet and
sometimes visible from turbine outlet depending on whether or not the wastegate flap is
opened for inspection.
 Do not replace turbocharger or turbine housing for a Grade 1 crack.
Grade 2: Crack that has progressed from the tongue and into the turbine profile but no
wheel rub has occurred.
 Do not replace turbocharger or turbine housing for a Grade 2 crack.
Grade 3: Turbine housing is cracked and distorted which has allowed turbine wheel to
rub housing.
 Replace complete turbocharger only if there is wheel rub.
External: These cracks allow exhaust gases to leak to the atmosphere.
 External turbine housing crack without wheel rub - replace turbine housing.
 External turbine housing crack with wheel rub - replace the complete turbocharger.
HE300WG Turbine Housing Reuse Guidelines
Grade 1 Cracks - Figures 1 - 4 below.
Grade 1 Crack - At tongue or wastegate port.
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Figure 1
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Figure 2
Figure 3
NOTE: Cracks in the turbine housing are stress relief cracks. This type of crack is not
miles or hours dependent.
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Figure 4
Figure 4 Descriptions
1. Crack propagating from tongue.
2. Crack does not enter profile.
3. Rust, natural gas combustion produces a lot of water.
Grade 2 Cracks - Figures 5 and 6 below.
Grade 2 Crack - Crack has progressed into profile - No
wheel rub. Unconditional Reuse - do not replace the
turbocharger or turbine housing.
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Figure 5
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Figure 6
Grade 3 Cracks - Figures 7 and 8 below.
Grade 3 Crack - Turbine housing has distorted - Wheel
Has Rubbed. Replace the turbocharger.
Figure 7
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Figure 8
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Figure 9 - Turbocharger Turbine Wheel Rubbing
External Cracks - Figures 10 - 13 below.
External Crack




Replace the turbine housing if there is no turbine wheel rub.
If the turbine wheel has rubbed the turbine housing, replace the turbocharger.
Figure 10
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Figure 11
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Figure 12
Figure 13
NOTE: Use the above guidelines and the below procedures, if necessary, to determine
the correct actions to be taken to repair or replace the turbocharger.
Use the following manuals and procedures for additional turbine housing reuse information:




ISL G CM2180 Service Manual, Bulletin 4021649. Refer to Procedure 010-033 in
Section 10.
ISX12 G CM2180 EJ Service Manual, Bulletin 4310682. Refer to Procedure 010-033 in
Section 10.
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Page 14 of 14
Document History
Date
2014-7-16
2015-3-18
2015-3-26
Details
Module Created
Improve quality of pictures
Updated pictures
Last Modified: 30-Mar-2015
Copyright © 2000-2010 Cummins Inc. All rights reserved.
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