Cummins ISX11.9 CM2250 – Service Manual 010-033   Turbocharger

NOTE: Brush away any loose dirt from around the area of air handling connections to avoid contamination of the interior of the engine.

If turbocharger blade damage is suspected, do the following:

• Remove the intake pipe from the turbocharger. Refer to the OEM service manual.
• Inspect the turbocharger compressor impeller blades for damage.
• Replace the turbocharger if damage is found.

If the turbocharger compressor impeller is damaged, do the following:

• Inspect the intake piping and filter element for damage.
• Repair any damaged parts before operating the engine.

Inspect the turbocharger turbine wheel.

• Remove the aftertreatment adapter pipe from the turbocharger. Refer to Procedure 011-043 in Section 11.
• Inspect the turbine wheel for damage.
• Replace the turbocharger if any damage is found.

If a turbocharger compressor seal leak is suspected, do the following:

• Inspect the compressor intake and discharge for oil.
• If oil is present in the compressor intake, as well as in the discharge, check upstream from the turbocharger for the source of the oil.
• If oil is present only in the discharge side, check for intake restriction. Refer to Procedure 010-031 in Section 10.
• If no intake restriction is found, replace the turbocharger.
• If no boost leak is found, check the oil drain of the turbocharger for restriction. Refer to Procedure 010-045 in Section 10.
• If no restriction in the oil drain is found, replace the turbocharger.

If a turbocharger turbine seal leak is suspected, do the following:

• Add one unit of fluorescent tracer, Part Number 3376891, to each 38 liters [10 gal] of engine lubricating oil.

NOTE: Before starting the engine, install all of the turbocharger air plumbing.

• Operate the engine at low idle for 10 minutes.

• Shut the engine off.
• Allow the turbocharger to cool.
• Remove the air intake pipe and compressor discharge piping from the turbocharger. Refer to the OEM service manual
• Remove the aftertreatment adapter pipe from the turbocharger. Refer to Procedure 011-043 in Section 11.

• Use a high-intensity black light, Part Number 3163337 (100 watt), or 3163338 (50 watt), to inspect the turbine outlet for leaks.

A dark blue glow indicates a fuel leak. A yellow glow indicates an oil leak.

• If oil is found in the exhaust outlet of the turbine housing, remove the oil drain line and check for restrictions. Refer to Procedure 010-045 in Section 10.
• Clear any restrictions found and/or replace damaged components as required.

• Check the engine breather or the crankcase vent tube for restrictions. Clear any restrictions and/or replace any damaged components. Refer to Procedure 003-001 in Section 3.
• Check the engine crankcase ventilation filter assembly for excessive restriction or blockage. Refer to Procedure 003-019 in Section 3.

• If the oil drain line is not restricted, remove the turbocharger. See the Remove section in this procedure.

• Use a high-intensity black light, Part Number 3163337 (100 watt) or 3163338 (50 watt), or equivalent, to inspect the turbine inlet for leaks.

A yellow glow indicates an oil leak.

If a yellow glow is not seen in the turbine inlet, replace the turbocharger.

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.

If a turbocharger internal coolant leak is suspected, use the turbocharger coolant leak test kit, Part Number 2892101, 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 cylinder block and install the adapter fitting for the pressure regulator supplied in turbocharger coolant leak test kit, Part Number 2892101.

• Install the M12 banjo block-off fitting from the turbocharger coolant leak test kit, Part Number 2892101, at the turbocharger electric actuator coolant outlet port to block off the coolant outlet of the electric turbocharger actuator.

NOTE: Make sure the banjo sealing washers are properly installed when installing the block-off fittings.

• Install the M12 banjo block-off fitting from the turbocharger coolant leak test kit, Part Number 2892101, to the end of the turbocharger bearing housing coolant line, located at the rocker housing, to block off the turbocharger bearing housing.

NOTE: Make sure the banjo sealing washers are properly installed when installing the block-off fittings.

• Use shop air supply to pressurize the turbocharger to 276 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.
• If the pressure decreases and the hose connections are not leaking, replace the turbocharger.
• If the pressure does not decrease, proceed to checking for internal leaks in the turbocharger electronic actuator.

• Connect a turbocharger coolant leak test kit, Part Number 4919763, by connecting the banjo fitting and pressure gauge to the turbocharger electronic actuator coolant inlet and capping the turbocharger electronic actuator coolant outlet.

NOTE: Make sure the banjo sealing washers are properly installed when installing the block-off fittings.

NOTE: For access, the turbocharger compressor outlet connection may need to be removed. Refer to Procedure 010-132 in Section 10.

• Use shop air supply to pressurize the turbocharger to 276 kPa [40 psi].
• Close the air pressure regulator.
• Watch for the pressure to decrease. 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.
• If the pressure decreases and the hose connections are not leaking, replace the turbocharger bearing housing.
• If the pressure does not decrease and the hose connections are not leaking, replace the electric turbocharger actuator.

Compare the assembly number (1) on the turbocharger dataplate with the turbocharger specified in the engine control parts list (CPL) number (2) listed on the engine dataplate.

If the correct turbocharger was not installed, remove it and install the correct turbocharger.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

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.

NOTE: Brush away any loose dirt from around the area of the air handling connections to avoid contamination of the interior of the engine.

• Drain the cooling system. Refer to Procedure 008-018 in Section 8.
• Remove any OEM air cleaner and charge-air cooler plumbing needed to remove the turbocharger. Refer to the OEM service manual.
• Remove the air inlet connection. Refer to Procedure 010-022 in Section 10.
• Remove the turbocharger compressor outlet connection. Refer to Procedure 010-132 in Section 10.
• Disconnect the turbocharger speed sensor. Refer to Procedure 019-390 in Section 19.
• Disconnect the turbocharger compressor air inlet temperature sensor. Refer to Procedure 019-395 in Section 19.
• Remove the turbocharger coolant hoses. Refer to Procedure 010-041 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 aftertreatment injector adapter tube pipe. Refer to Procedure 011-043 in Section 11.
• Use protective caps from the Air Handling Clean Care Kit, Part Number 4919799, to cover open points.

WARNING  This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component.

CAUTION  When installing a lifting eye, be sure the shoulder of the lifting eye is bottomed against bearing housing. Failure to do so can result in failure of the lifting eye and personal injury.

CAUTION  If the lifting eye is installed in the turbocharger bearing housing, it is to be used exclusively for turbocharger removal and installation. It is not to be used in removal of the exhaust manifold, or engine. Doing so will cause damage to the turbocharger.

CAUTION  The turbocharger actuator must not be used as a lifting mechanism. Doing so will cause damage to the turbocharger actuator.

Thread a lifting strap around the turbocharger bearing housing.

Care must be taken not to damage the turbocharger compressor inlet air temperature sensor and the turbocharger speed sensor when removing the turbocharger from the engine.

NOTE: Spiral locknuts are utilized to reduce the risk of the turbocharger mounting nuts falling off.  However these nuts have more of a tendency to NOT loosen freely. If the nut does not loosen freely, split the nuts to avoid breaking a mounting stud.

Remove the nuts from the turbocharger studs and remove the turbocharger.

Remove the turbocharger and discard the gaskets.

Cover the turbocharger exhaust inlet port with heavy tape or a protective cap from the Air Handling Clean Care Kit, Part Number 4919799.

Cover the opening on the exhaust manifold with heavy tape.

Inspect the variable geometry actuator and mechanism for proper operation. Refer to Procedure 010-134 in Section 10.

Inspect for cracks in the turbocharger and compressor casings.

Replace the turbocharger if through cracks in the outer walls are found.

Inspect for cracks on the turbine inlet and exhaust mounting flanges. Replace the turbocharger if any cracks are found.

NOTE: All openings on the turbocharger, including the turbine inlet connection, must be plugged with caps from the Air Handling Clean Care Kit, Part Number 4919799, during flange cleaning.

Clean the turbocharger and exhaust manifold where the retaining nut contacts the turbocharger and exhaust manifold.

Clean the mating surfaces with Scotch-Brite™ 7448 abrasive pad.

After abrasive cleaning, wipe debris from both surfaces with a clean shop towel.

The surface under the mounting nuts must be free of dirt, rust, or any other debris, before applying anti-seize compound, Part Number 3823097.

Replace the turbocharger if any leaks are found.

Check for evidence of coolant in the oil supply and oil drain fittings.

Insepct the turbocharger compressor V-band outlet and the discharge elbow V-band connection for dents or fretting.

Replace the turbocharger or turbocharger compressor outlet connection, if damaged, to prevent compressed air leaks.

Inspect the compressor wheel for signs of rubbing against the compressor cover. Replace the turbocharger if rubbing evidence is seen.

Use light finger pressure to push the compressor wheel. If the compressor wheel contacts the cover, replace the turbocharger.

If the engine experiences a turbocharger malfunction or any other occasion where oil or debris is put into the charge-air system, the charge-air system must be inspected and cleaned. Refer to Procedure 010-027 in Section 10.

Check the axial movement of the turbocharger wheels and shaft.

Turbocharger Axial Clearance

If the turbocharger axial clearance is not within specifications, the turbocharger must be replaced.

Check the radial movement of the turbocharger wheels and shaft.

Use light finger pressure to push the compressor wheel toward the side of the compressor housing.

Repeat the procedure for the turbine wheel and housing.

Replace the turbocharger if either wheel contacts the housing.

If the engine experiences turbocharger damage or any other occasion where oil or debris is put into the charge-air system, the charge-air system must be inspected and cleaned.

Inspect the charge-air cooler. Refer to Procedure 010-027 in Section 10.

Inspect the air intake manifold. Refer to Procedure 010-023 in Section 10.

Remove the protective caps and heavy tape from the Air Handling Clean Care Kit, Part Number 4919799, used to cover open points in the air handling system.

WARNING  Remove the plastic shipping plugs in the turbocharger bearing housing for the oil supply and oil drain. Failure to remove the oil supply shipping plug will damage the turbocharger. Failure to remove the oil drain shipping plug will damage the oil compressor seal. Engine oil can be sucked through the air intake system and cause engine acceleration and overspeeding that can result in a fire, an explosion, and extensive property damage.

Remove the plastic shipping plugs from the oil drain and oil supply holes located in the turbocharger bearing housing.

Install the oil supply fitting. Refer to Procedure 010-046 in Section 10.

Apply a film of high-temperature anti-seize compound, Part Number 3823097 or equivalent, to the turbocharger mounting studs and to the flange area on the retaining nuts. Properly applying anti-seize compound will reduce the possibility of the nuts loosening over time.

WARNING  This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component.

CAUTION  When installing lifting eye, be sure the shoulder of the lifting eye is bottomed against bearing housing. Failure to do so can result in failure of lifting eye and personal injury.

CAUTION  If a lifting eye is installed in turbocharger bearing housing, it is to be used exclusively for turbocharger removal and installation. It is not to be used in removal of the exhaust manifold, or engine. Doing so will cause damage to the turbocharger.

CAUTION  Do not rotate the turbocharger turbine housing. Loosening turbine v-band and rotating the turbine housing can cause damage to internal variable geometry mechanism.

CAUTION  The turbocharger actuator must not be used as a lifting mechanism. Doing so will cause damage to the turbocharger actuator.

Thread a lifting strap around the turbocharger bearing housing. Take care to not bend the turbocharger and actuator coolant lines when lifting the turbocharger.

Care must be taken not to damage the turbocharger compressor inlet air temperature sensor and the turbocharger speed sensor when installing the turbocharger.

Install a new gasket, the turbocharger, and the four mounting nuts. Be sure the mounting spacers are properly positioned.

Tighten the mounting nuts. After all four mounting nuts are tightened, tighten the first mounting nut again.

If installing a new turbocharger, it may 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 V-band between the turbocharger bearing housing and the turbocharger compressor housing.

Rotate the turbocharger compressor housing to properly align with the charge-air cooler piping.

Tighten the V-band clamp.

WARNING  The turbocharger speed sensor harness must be tied up and away from any heat sources and hard or sharp surfaces. Failure to do so will cause damage to the harness.

WARNING  Do not install cable ties directly over the sensor connector. Doing so can damage the connector. Tie the speed sensor wiring harness on either side of the connectors.

Use cable ties to secure the turbocharger actuator harness and the turbocharger speed sensor harness away from any heat sources and hard or sharp surfaces.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

• Remove the protective caps and heavy tape from the Air Handling Clean Care Kit, Part Number 4919799, used to cover open points in the air handling system.
• Install the turbocharger coolant hoses. Refer to Procedure 010-041 in Section 10.
• Install the turbocharger oil supply line. Refer to Procedure 010-046 in Section 10.
• Install the turbocharger oil drain line. Refer to Procedure 010-045 in Section 10.
• Connect the turbocharger actuator electrical connector.
• Connect the turbocharger speed sensor. Refer to Procedure 019-390 in Section 19.
• Connect the compressor inlet temperature sensors. Refer to Procedure 019-395 in Section 19.
• Install the aftertreatment injector adapter pipe. Refer to Procedure 011-043 in Section 11.
• Install the air inlet connection. Refer to Procedure 010-022 in Section 10.
• Install the turbocharger compressor outlet connection. Refer to Procedure 010-132 in Section 10.
• Install any OEM air cleaner and charge-air cooler plumbing that was removed. Refer to the OEM service manual.
• Fill the cooling system with coolant. Refer to Procedure 008-018 in Section 8.
• Operate the engine until the coolant temperature reaches 82°C [180°F].
• Check for air, coolant, and oil leaks.

If a malfunction resulted in coolant, oil, excessive fuel, or excessive black smoke entering the exhaust system, the aftertreatment system must be inspected. Refer to Procedure 014-013 in Section 14.