Zeki turbo

Cause of Failure

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Lack of Lubrication or Oil Degradation

Causes:

- Low engine oil levels

- Obstructions in oil feed lines

- Build up of burnt oil in center housing

- Excessive Temperature

- Inferior oil quality.

Symptoms:

- Oil leakage

- Noise

- Loss of power

- Excessive smoke

- Excessive oil consumption

Consequences:

- Excessive wear of journal bearings, thrust bearing, and thrust collar.

- An imbalance causing excessive wear to rotating components.

- Wear of sealing surfaces of back plate and thrust collar.

- Piston ring failure or leakage.

Contaminated Oil

Causes:

- Saturated oil filter

- Recycled Oil

- A rebuilt engine with impurities within the oil passages.

- Burnt oil from high temperatures.

- Residue from incomplete combustion.

Symptoms:

- Oil leakage

- Noise

- Loss of power

- Excessive smoke

- Excessive oil consumption

Consequences:

- Scoring and wear of journal bearings

- Scoring and wear of thrust bearing and thrust collar.

- Imbalance

- Failed components

Foreign Body Ingestion

Causes:

- Materials ingested into either the compressor ,or turbine side of the turbo.

- Damage to the compressor side suggests an insufficient/dirty air filtration system, or a damaged air intake tubes.

- Damage to the turbine suggests damage to the engine such as parts of the pistons ,or valves.

Symptoms:

- Loss of power

- Noise

- Excessive smoke

Consequences:

- Damage to the wheels.

- Imbalance to the rotating assembly.

- Excessive wear to the rotating assembly.

Hot Shutdown

Causes:

- Frequent turning off the engine at high speed.

- Inferior oil quality.

- High operating temperature.

Symptoms:

- Oil leakage.

- Excessive smoke

Consequences:

- Extensive deposits of carbon and shellac in the turbine end seal parts and bearing system.

- In early stages of failure, bearing clearances are decreased by the deposits.

- As the problem continues, the deposits break up, scoring and wearing the bearing bore, journal bearing, and shaft.

Excessive Exhaust Gas Temperature

Causes:

- Engine operation in altitude.

- Incorrect engine air/fuel ratios.

- Malfunctioning exhaust oxygen sensor or other engine control system.

- Malfunctioning EGR valve.

Symptoms:

- Loss of power.

- Noise.

- Excessive smoke.

- Oil leakage.

Consequences:

- Erode, distort, or crack the turbine housing.

- Wheels rub the end housings.

- Imbalance to the rotating assembly.

- Thrust bearing / journal bearing collapses.

Surge or Shaft Motion Operation

Causes:

- Engine operation in altitude.

- Application not in accordance to the standards.

- Restricted air admission systems.

- Malfunctioning EGR or PCV valves.

Symptoms:

- Loss of power.

- Noise.

- Excessive smoke.

- Oil leakage.

Consequences:

- Damage to the compressor wheels.

- Imbalance to the rotating assembly.

- Thrust bearing / journal bearing collapses.

Broken Compressor Wheel

Causes:

- Low cycle fatigue operation.

- Engine operation in altitude.

- Application not in accordance to the standards.

- Wheel blades design.

Symptoms:

- Loss of power.

- Noise.

- Excessive smoke.

- Oil leakage.

Consequences:

- Compressor wheel burst.

- Compressor wheel broken as a 'slice of pizza'.

- Imbalance to the rotating assembly.

- Excessive wear to the rotating assembly.

Excessive Exhaust Back Pressure

Causes:

- Excessive engine brake operation.

- Restricted exhaust systems.

- Restricted air admission systems.

- Malfunctioning EGR or PCV valves.

Symptoms:

- Loss of power.

- Noise.

- Excessive smoke.

- Oil leakage.

Consequences:

- Back of turbine wheel rubbing center housing or heat shield

- Scoring and wear of thrust bearing and thrust collar.

- Imbalance to the rotating assembly.

- Excessive wear to the rotating assembly.

Overspeed

Causes:

- Incorrect engine air/fuel ratios

- Malfunctioning exhaust oxygen sensor or other engine control system.

- Malfunctioning wastegate actuator or its wrong calibration.

- Application not in accordance to the standards.

Symptoms:

- Loss of power.

- Noise.

- Oil leakage.

Consequences:

- Scoring the wheels to the housings.

- Imbalance to the rotating assembly.

- Excessive wear to the rotating assembly