THERE
IS A
TEARDOWN ANALYSIS DIMENSIONAL ANALYSIS
NON-GENUINE TURBO COMPONENTS
ComponentMeets Specifications Risk Level
Turbine Housing*No High
Journal BearingsNo Medium
Thrust BearingsNo Medium
Speed SensorNo Medium
Thrust BearingsNo Medium
Bearing HousingNo Low
Inlet StudsNo Low
*TURBINE HOUSING
Risk Level: High
Meets Specifications: No
NON-GENUINE TURBO COMPONENTS
ComponentMeets Specifications Risk Level
Journal Bearings* NoMedium
Thrust BearingsNoMedium
Nozzle RingNoMedium
Diffuser NoLow
*JOURNAL BEARINGS
Risk Level: High
VG mechanism was gritty and restricted movement. The shroud plate was reused, and cleaning abrasive was found inside.
■ Potential Impact: Damage to turbine wheel and binding in VG mechanism could render turbo inoperable.
reused, and they failed to meet roundness and straightness specifications.
■ Potential Impact: Diminished performance and early failure
NON-GENUINE TURBO COMPONENTS
*THRUST BEARINGS
Risk Level: Medium
Meets Specifications: No
TESTING
NON-GENUINE TURBO COMPONENTS
■ Potential Impact:
The high-risk results we found from functional testing could lead to a number of possible negative outcomes: increased cost to recalibrate, additional hours of service support, and reduction of turbo life.
Diffuser No
Journal Bearings No
Thrust Bearings*No
Nozzle RingNo
Material composition incorrect (high levels of aluminum, lead, zinc, silicon, phosphorus and sulfur with low bismuth)
■ Potential Impact: Diminished service life and potential early failure.
Type of Test Pass / Fail
Actuator StepAll FailedHigh
Leak TestHalf FailedHigh
Functional TestAll FailedHigh
Speed SensorAll PassedN/A
ACTUATOR ANALYSIS
NON-GENUINE TURBO COMPONENTS
Issue Observed
Low-grade replacement components in circuit board assembly
Added wiring and heat dissipator causing pinched wiring
Added heat dissipator pressing on electronic chip (could crack chip)
Lack of vibration dampening in circuit board compartment
■ Impact:
Teardown High
Teardown High
Teardown High
Teardown High
VG unable to reach 100% of commanded position Electronic InterfaceHigh
Every issue listed above could cause reduced durability, decreased performance, fault codes and EGR issues. These are only the most severe issues observed from testing non-genuine actuators.
TESTING THE DIFFERENCE
THERE’S NO SUBSTITUTE FOR GENUINE QUALITY
OBJECTIVE
Cummins engineers conducted lab testing on non-genuine remanufactured turbochargers that competitors sold as replacements for ISX and ISB engines.
BACKGROUND
The non-genuine turbos and actuators were placed through engine performance testing, teardown and thorough component analysis to see how they faired against the requirements put on Genuine Holset Reman turbochargers.
The non-genuine turbos and actuators displayed issues that could result in reduced service life of the turbos, as well as progressive damage and engine failure.
■ Remanufactured to same standards as new turbos using a 5-step process (disassembly, cleaning, inspection, restoration and testing) ■ Durable and efficient turbo operation ■ Prolonged engine life
Inadequate material composition
Reuse pivotal components that Cummins requires to be replaced with new
■ Potential for turbo failure leading to catastrophic engine damage