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    Failure Diagnosis: Turbocharger Guidelines

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    Tan Kokkiang
    The document provides guidelines for diagnosing turbocharger failures, listing potential causes such as foreign object damage, insufficient lubrication, dirt in the oil, and carbon buildup. It advises identifying the fault before replacing the turbocharger and never operating with a suspect or noisy turbocharger.

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    © All Rights Reserved
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    Failure Diagnosis: Turbocharger Guidelines

    Uploaded by

    Tan Kokkiang
    101 views1 page
    The document provides guidelines for diagnosing turbocharger failures, listing potential causes such as foreign object damage, insufficient lubrication, dirt in the oil, and carbon buildup. It advises identifying the fault before replacing the turbocharger and never operating with a suspect or noisy turbocharger.

    Original Description:

    Holset

    Original Title

    Holset data

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    The document provides guidelines for diagnosing turbocharger failures, listing potential causes such as foreign object damage, insufficient lubrication, dirt in the oil, and carbon buildup. It advises identifying the fault before replacing the turbocharger and never operating with a suspect or noisy turbocharger.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    101 views1 page

    Failure Diagnosis: Turbocharger Guidelines

    Uploaded by

    Tan Kokkiang
    The document provides guidelines for diagnosing turbocharger failures, listing potential causes such as foreign object damage, insufficient lubrication, dirt in the oil, and carbon buildup. It advises identifying the fault before replacing the turbocharger and never operating with a suspect or noisy turbocharger.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 1

    Turbocharger

    Failure Diagnosis Guidelines


    Foreign object damage to impeller Foreign object damage to turbine wheel
    Never continue to operate an engine with a
    suspect or noisy turbocharger as this could
    result in total engine failure.
    Impact
    Impact damage caused by foreign material entering the turbine housing
    damage or compressor housing is clearly visible on the turbine wheel
    or impeller.

    Never continue to operate a turbocharger with damaged blades as the


    rotor balance will be affected and this could impact its service life.

    Effects of using silicone sealants Insufficient lubrication oil

    Insufficient oil supply can be attributed to the following:


    ■■ Re-fitting a turbocharger without adequate priming\
    ■■ Long periods of non-use
    Insufficient ■■ Broken or restricted oil feed pipe
    ■■ Low engine oil pressure due to malfunctioning lubrication system

    oil supply ■■ Low or no oil in sump


    ■■ The use of sealants, which can restrict the oil flow
    ■■ Not priming a replacement oil filter with new oil. If this cannot \琀屴\
    be done then crank the engine with no fuel to establish oil pressure
    ■■ Do not exceed idle conditions until oil pressure is established.

    Dirt scored shaft Dirt scored bearing


    Dirty oil damages the turbocharger by causing heavy scoring of critical
    bearing surfaces. To avoid damage, oil and filters should be of a quality
    recommended by the engine manufacturer. These should be changed
    when a new turbocharger is fitted and at regular intervals according to the
    vehicle/engine manufacturer’s specification.
    Dirt in oil Dirty oil damage could result from:
    ■■ Blocked, damaged or poor quality oil filter
    ■■ Dirt introduced during servicing
    ■■ Engine wear or manufacturing debris
    ■■ Malfunctioning oil filter by-pass valve
    ■■ Degraded lubrication oil.

    Bearing damage due to hot shutdown Carbon build-up on shaft Failure from excessive exhaust temperatures or hot shutdown of engine
    results in carbon build-up. It is recommended that you idle the engine for
    two to three minutes to cool the bearing system before shutting down.
    Turbine end heat soak into the bearing housing results in oil carbonisation
    and corrosion of the bearing system. The main damage occurs to the

    Carbon shaft seal ring and grooves, turbine end bearing and bearing housing oil
    drain cavity blockage.

    build-up Carbon build-up can be caused by:


    ■■ Hot shutdown of engine
    ■■ Degraded oil quality carbonising in service
    ■■ Infrequent oil change intervals causing oil breakdown in service
    ■■ Air and gas leaks
    ■■ Faulty fuel injector pump/injectors.

    Before changing your turbocharger, please make sure that you have correctly identified the cause of the fault.
    Excess smoke Engine lacks power Noisy/Whistling Seized/Sluggish Worn/Excessive clearance

    Caused by: Caused by: Often the noise comes from air/gas If the turbocharger rotor assembly A turbocharger has specific axial
    • Dirty air cleaner • Dirty air cleaner leakage due to pre-turbine exhaust has seized or is tight to rotate, and radial rotor clearances. These
    • Air intake system restriction • Air intake system restriction gas or air/boost leaks. this is often due to lubricating oil are sometimes mis-diagnosed
    • Cracked mounting flange/gasket • Cracked mounting flange/gasket degregation, which can cause a high as ‘worn bearings’ (See engine
    \琀屴 missing \琀屴 missing Check all joints. If noise continues, build up of carbon in the bearing manual or nearest authorised
    • Fuel pump/injectors/valve timing • Exhaust for foreign object check turbocharger clearances and housing interior, restricting rotation. Holset distributor). If the clearances
    \琀屴 incorrectly set \琀屴 restriction wheels for housing contact. Insufficient or an intermittent drop in are out of specification the cause
    • Wastegate mechanism set • Fuel pump/injectors/valve timing oil pressure can cause the rotor to could be attributed to a lubricating
    \琀屴 incorrectly \琀屴 incorrectly set seize, as can introducing dirt into the oil problem, i.e. insufficient oil, dirt
    • Turbocharger damaged. • Burnt valves and/or pistons lubricating oil. ingress, oil contamination with
    • Turbocharger damaged. coolant.

    Remember, if the root cause of the problem is not identified and corrected, your problem will remain!

    For more information visit:

    www.holsetaftermarket.com

    All rights reserved.


    VGT, Command Valve and Super MWE are trademarks of Cummins Turbo Technologies Ltd.
    Holset and the Holset Logo are registered trademarks of Cummins Turbo Technologies Ltd.
    Cummins and the Cummins logo are registered trademarks of Cummins Inc.
    Bulletin 5544148 7/18 Rev.06 Ref. DA/CM Effect Date: 01:12
    ©2014 Cummins Turbo Technologies Ltd.

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