HX25/25W/27W Service Repair Manual Introduction
Installation Data
1:4
1. 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.
2. It is important that intake and exhaust systems are fitted in accordance with the recommendations of
the Equipment and Engine manufacturers. Limiting mass inertia loading is critical to turbocharger whole
life operation. Maximum engine vibration input must not exceed 8.9g.
3. The air filter must remove particles greater than 5 µm 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 capable of withstanding depressions up to 6.9 kPa
(1.0 lbf/in
2
).
4. 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.
5. Exhaust systems must be capable of operating at exhaust back pressures of up to 10 kPa (1.5 lbf/in
2
).
This limit is increased to 13.4 kPa (2.0 lbf/in
2
) if a catalytic converter is fitted. Exhaust brake
applications are permitted to impose 450 kPa (65.3 lbf/in
2
) back pressure.
6. Oil should be filtered to 10µm with efficiency of 60% TWA (Time Weighted Average) /20 µm with
efficiency of 85% TWA. Efficiency assessed using ISO Standard 4572/SAE J 1858.
7. The oil quality must be as specified by the engine manufacturer and will be a minimum API SE - CD
(MIL - L- 2104C) specification. Recommended oil change intervals are 5000 to 10,000 km (250 to 500
h) depending on duty. Improved life can be obtained by using super high performance diesel (SHPD)
oils, particularly in industrial applications which use extended oil drain periods.
8. Normal oil temperature is 95+/-5°C (203+/-9°F). It should not exceed 120°C (248°F) under any operating
condition.
9. Any pre-lube oil must be clean and meet the minimum CD classification.
10. The attitude of turbine housing, bearing housing and compressor cover is fixed. During installation, do
not attempt to rotate these components. Inclined turbocharger installation is not recommended. If an
installed angle is necessary, oil inlet centreline must be +/- 10 degrees from vertical and rotor centreline
+/- 5 degrees from horizontal.
11. Holset permits oil return pipes to decline at an overall angle of not less than 30 degrees below horizontal.
All turbocharger applications require a pipe of internal diameter greater than 14 mm which has integrated
connectors. To ensure oil returns into the engine under all operating conditions, the return connection into
the engine sump must not be submerged and the outlet flange of the turbocharger must be 50mm above
the maximum oil level of the engine sump pan. Crankcase pressure should be limited ideally to 0.8 kPa
(0.12 lbf/in
2
) but 1.4 kPa (0.20 lbf/in
2
) can be accepted by reference to Holset.
12. Oil pressure of 150 kPa (20 lbf/in
2
) must show at the oil inlet within 3 - 4 seconds of engine firing to
prevent damage to turbocharger bearing system. A flexible supply pipe is recommended. Turbocharger
speed must not exceed 90,000 rev/min until 150 kPa (20 lbf/in
2
) is achieved.
13. The minimum oil pressure when the engine is on load must be 210 kPa (30 lbf/in
2
). Recommended full
load rated speed operating pressure is 350 kPa (50 lbf/in
2
) although 500 kPa (72 lbf/in
2
) is permitted
during cold start up. Under idling conditions pressure should not fall below 80 kPa (11.5 lbf/in
2
).
14. Recommended oil flows for the turbochargers are 0.4 litre/min at idle and 1.4 litre/min at maximum engine
speed.
15. Do not use liquid gasket substances or thread sealant as any excess can enter the turbocharger oil to
obstruct flow.
Note:
100 kPa = 1 bar (14.5037 lbf/in
2
= psi).
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