Failure Modes of Turbochargers

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Producto: ENGINE - MACHINE

Modelo: 3306 ENGINE - MACHINE 64Z
Configuración: 3306 Industrial Engine 64Z05381-UP
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Failure Modes of Turbochargers{1052}
Número de medio -SEBF9085-01 Fecha de publicación -31/05/2006 Fecha de actualización -31/05/2006
i02509537
Failure Modes of Turbochargers{1052}

SMCS - 1052
Caterpillar Products: Engines with ACERT Technology Machine Engines with ACERT Technology
Engine:Truck All
Engine: All Commercial Gas Engines
Industrial Engine:with Turbochargers All
Machine Engines: All
Marine Engine:with Turbochargers All
Introduction
Every effort has been made in publishing this technical document in order to provide the most current
information and applicable information that is known to Caterpillar. Caterpillar makes ongoing changes and
improvements to the products. This guideline must be used with the latest technical information that is
available from Caterpillar to ensure all changes and improvements are incorporated.
For additional information about this guideline, consult Repair Process Engineering of the Marketing &
Product Support Division at 1 (309) 675-5434.
Summary
These instructions give failure modes of turbochargers for engines using the basic principles of wear and
fracture to determine the most probable root cause of failure. Maintenance records for the engine should be
examined before failure analysis begins. Inadequate maintenance can shorten turbocharger life significantly.
Check in order to ensure that recommended oil change intervals have been followed by using quality filters
and lubricants of the appropriate grade and viscosity. If the results are available, review the results from the oil
and coolant analysis.
This manual should be used with the additional documents in the reference section.
References
z Guideline for Applied Failure Analysis, SEBV0554, "Principles of Wear"
z Guideline for Applied Failure Analysis, SEBV0552, "Principles of Fracture"
z Guideline for Applied Failure Analysis, SEBV0550, "Turbochargers"
Nomenclature for Turbochargers
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/s... 18/06/2008
Illustration 1 g01232438
Use this cutaway view of a turbocharger in conjunction with the illustration of the nomenclature in order to
understand the internal components and operation of a turbocharger.
The correct turbocharger installation is critical to achieving normal turbocharger life. This includes avoiding
contamination. Proper alignment and lubrication ensure minimal flexing and stress at start-up and proper
alignment and lubrication minimize damage from thermal growth during operation.
This compressor housing was not installed correctly. This allowed contact between the compressor wheel and
the compressor housing. The large diameter of the compressor wheel made contact on one side of the housing
and the small diameter of the compressor wheel made contact around half of the housing.
This turbocharger shaft is bent. Bent turbocharger shafts can result from rough handling, problems during
assembly, problems during shipping, or installation of the housing.
The fins on this compressor wheel have made contact with the housing. The damage on the fins is on the
opposite sides of the wheel and at the opposite ends of the fins. This type of damage can be the result of a bent
shaft or an unbalanced compressor wheel.
Abrasive wear and adhesive wear produce excessive wear on the journal bearing, movement of the shaft,
possible contact of the wheel with the housing, and oil leaks into the housing.
Contact of the wheel with the housing typically indicates excess clearances in the shaft, bearing, or the
cartridge. If the turbocharger is new, check for correct configurations of the part number. If the turbocharger
has been in service, measure movement of the shaft and determine the type of wear.
Wear of the journal bearing can be measured with a dial indicator. Check the specifications for the correct
clearance.
Excessive wear of the thrust bearing can result from abrasive wear, adhesive wear, or restrictions in the intake
and exhaust systems. Always check for intake and exhaust restrictions and perform the recommended service
procedures before installation, during installation, and after installation of a replacement turbocharger.
Abrasive wear is due to contaminated lube oil and abrasive wear produces excessive wear of the journal
bearing, movement of the shaft, possible contact of the wheel with housings, and oil leaks into the housings.
The parts that can be viewed from the oil return port will appear normal but the parts have excessive
clearances. Flush the inside of the cartridge with a clean solvent and collect the solvent as the solvent drains
out of the cartridge. Analyze the fluid in order to determine the contaminant and the source.
Colors of tempering that are found on the shaft at the journal bearings indicate adhesive wear. Adhesive wear
is caused by metal-to-metal contact. Determine the reason for insufficient protection for the shaft and bearings
by the film of lubrication. Some possible reasons for insufficient protection are listed below.
z Dry start or start-ups at full load
z Wrong oil viscosity
z Lack of oil
z Low oil pressure
High exhaust temperatures can cause the following damage.
z Burn the painted surface onto the center section.
z Produce oxides on turbocharger parts.
z Bake the oil in the cartridge.
High operating temperatures and hot shutdowns can cause the lubricating oil film on internal turbocharger
parts to vaporize. When oil vaporizes, carbon solids are deposited on the surface of parts. These residues can
create contamination and abrasive wear. The residues may also cause an interference fit between the shaft and
journal bearings which can lead to adhesive smearing and excess clearances. Check the operation of the engine
and turbocharger, the application, the oil quality, and the oil change intervals.
The blue arrows point to the lines of dirt.
The fins were damaged when foreign material entered the turbocharger on the intake side of the compressor
wheel. Lines of dirt on the fins indicate that the turbocharger operated for some period of time after the
damage to the fins. Damage to the fin may cause an imbalance to the compressor wheel, or a fracture of the
compressor wheel or shaft.
Check the intake system in order to determine the way that the contaminated air is reaching the turbocharger.
Damage to the fins of the turbine wheel at the area of entry for the gas indicates that the foreign particles
entered the turbocharger from the exhaust manifold side. Determine the engine parts that failed causing
damage to the turbine wheel.
This compressor wheel has fractured through the center and this is referred to as a wheel burst. Notice the
smoother, lighter colored area on the fractured surface. This smoother area is a fracture that is caused by
fatigue and the result of cyclic centrifugal force. Check for inclusions in the material, machining marks in the
bore, a restricted intake system that allowed the turbocharger to go too fast, etc.
During manufacturing, the turbine wheels are welded by inertia to the turbocharger shafts. The air gap in the
center of the weld helps to stop the heat transfer between the wheel and the shaft.
This turbocharger shaft failed due to a weak weld. Notice that the surfaces of the weld are very smooth. The
weld area of the turbine wheel will not be attracted to a magnet because very little material from the steel shaft
adheres to the weld during the welding process.
The turbocharger shaft also fractured at the weld. In this situation, a magnet is attracted to the fractured surface
of the turbine wheel. The surface of the weld also appears rough.
The most probable root cause of failure in shafts was contact of the turbine wheel with the turbine housing
which interfered with wheel rotation and created wrapping of the shaft from inertia.
Also check the clearance of journal bearing. If the clearance is excessive, examine the turbocharger in order to
determine the type of wear that is responsible for the damage.
Copyright 1993 - 2008 Caterpillar Inc. Wed Jun 18 14:17:07 EST 2008
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3306 Industrial Engine 64Z05381-UP(SEBP1989 - 24) - Estructura del documento Página 1 de 12

Producto: ENGINE - MACHINE

Pautas de reutilización y recuperación

Failure Modes of Turbochargers{1052}

z Guideline for Applied Failure Analysis, SEBV0552, "Principles of Fracture"

z Guideline for Applied Failure Analysis, SEBV0550, "Turbochargers"

Nomenclature for Turbochargers

z Dry start or start-ups at full load

z Wrong oil viscosity

z Low oil pressure

High exhaust temperatures can cause the following damage.

z Burn the painted surface onto the center section.

z Produce oxides on turbocharger parts.

z Bake the oil in the cartridge.

damage to the turbine wheel.

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