3. 3
Service Training Malaga
AFA I
Lion DVD
In This Presentation
• Function
• Design
• Operation
• Normal wear
• Why Turbos Fail
CHAPTER: Turbochargers
6. 6
Service Training Malaga
AFA I
Lion DVD
Turbocharger Functions
• Normalize Air Supply
• Boost Air Supply
CHAPTER: Turbochargers
7. 7
Service Training Malaga
AFA I
Lion DVD
Normalizing
• Compensate for thinner Air
• Waste gate valve by-pass turbo boost
• Normal Power at high Altitudes
• Fuel deration at 2 150 m to avoid over speed
• Quieter Exhaust, better combustions and emissions
CHAPTER: Turbochargers
22. 22
Service Training Malaga
AFA I
Lion DVD
Design Free-floating journal bearings
Copper/tin/lead alloy or from aluminium
Lube holes or groove
CHAPTER: Turbochargers
24. 24
Service Training Malaga
AFA I
Lion DVD
Copper/tin/lead alloy or from aluminium
Design Thrust Bearing
Bearing stationary
Washer full shaft RPM
CHAPTER: Turbochargers
25. 25
Service Training Malaga
AFA I
Lion DVD
Design Seal Rings
High temperature resistant chrome alloy
Cold side cast iron
End gap
CHAPTER: Turbochargers
26. 26
Service Training Malaga
AFA I
Lion DVD
Design Housing
Cast aluminum alloy
Cast Iron
Cast ductile iron or nickel alloy
CHAPTER: Turbochargers
27. 27
Service Training Malaga
AFA I
Lion DVD
Design Heat Shield
Protects center housing from high
exhaust temperatures
CHAPTER: Turbochargers
30. 30
Service Training Malaga
AFA I
Lion DVD
Operation Air Restriction
Turbo spin 80 000 Rpm
Surface speed 30m/second
Energy stored in rotating
component can equal the
engine HP
CHAPTER: Turbochargers
37. 37
Service Training Malaga
AFA I
Lion DVD
• Lack of Lubrication
• Abrasive in the Oil
• High Exhaust Temperature
• Foreign Objects
• Turbo Problems
Why Turbos Fail
CHAPTER: Turbochargers
38. 38
Service Training Malaga
AFA I
Lion DVD
• Temper Colors/ Cooked Oil
• Adhesive Wear
• Weakened Metal
• Wheel Contact with Housing
• Wheel separation from Shaft
Lack of Lube Road-signs
CHAPTER: Turbochargers
55. 55
Service Training Malaga
AFA I
Lion DVD
Abrasive in the Oil Road-signs
• Scratches, Cuts, Grooves
• Little Heat Damage
• Rapid Wear
• Embedded Debris
CHAPTER: Turbochargers
56. 56
Service Training Malaga
AFA I
Lion DVD
Abrasive in the Oil Extended Oilchange Intervals
Excessive shaft motion
CHAPTER: Turbochargers
58. 58
Service Training Malaga
AFA I
Lion DVD
Abrasive in the Oil
Exhaust carbon cause fine abrasive cutting
Missing Hot side Seal
CHAPTER: Turbochargers
62. 62
Service Training Malaga
AFA I
Lion DVD
Abrasive in the Oil
New turbo failed after 3 weeks of service
CHAPTER: Turbochargers
63. 63
Service Training Malaga
AFA I
Lion DVD
Abrasive in the Oil
1. Debris size = pin head
2. Debris shape = spherical
3. Debris uniformity = same size
4. Debris color = black, blue, grey, silver.
5. Magnetic = yes
CHAPTER: Turbochargers
64. 64
Service Training Malaga
AFA I
Lion DVD
High Exhaust Temp. Road-signs
• Much Heat Damage
- Cooked Oil
- Oxidation
- Temper Colors
• Much Bearing Wear
CHAPTER: Turbochargers
67. 67
Service Training Malaga
AFA I
Lion DVD
Foreign Object Road-signs
• Wheel Blade Damage
• Bent Center Shaft
• Normal Bearing Wear
• Wheel Separation
CHAPTER: Turbochargers