PRESENTATION BY

TURBO ENERGY LIMITED

67, CHAMIERS ROAD,
CHENNAI - 28

COMPANY OVERVIEW
Turbo Energy Limited (TEL) incorporated in 1982.
TEL manufacturing plant is located at Pulivalam village in
vellore district, Tamilnadu.
TEL manufactures turbocharger range from KP 35 to K 37
(from 60 hp to 400 hp) in collaboration with Borg-Warner
Turbo System GmbH.
TEL exports turbochargers and turbocharger components to
BorgWarner Turbo Systems GmbH.
TEL is a QS 9000 certified company.
TEL has its marketing and engineering office at Chennai.
Regional offices at Chennai, Delhi, Kolkotta, Pune.

Turbo Energys Customers

Ashok Leyland Ltd
Bajaj Tempo Ltd
Bharat Earth Movers
Eicher Motors Ltd
General Motors India.
Greaves Cotton Ltd.
Hindustan Motors.
Kirloskar Oil Engines Ltd
Mahindra & Mahindra
Simpson & Co.
Swaraj Mazda Ltd
TATA Engineering

Means of increasing the power output

By Enlarging the swept Volume

- Results in a larger and heavier engine

By increasing the engine Speed

- Mechanical stability limits the power
- Engine efficiency drops at high speeds

By Turbocharging
- The combustion air is already pre-compressed before being supplied
to the engine.
- The engine aspirates the same volume of air, but due to higher
pressure, more air mass is supplied into the engine. Consequently more
fuel can be burnt.
- Thus, engine power output increases with the same speed and swept
volume.

Exhaust gas Turbocharging

In exhaust gas turbocharging the exhaust gas which would normally be

wasted, is used to drive a turbine. The turbine drives a compressor which
draws in filtered air and feeds this, at a higher pressure, to the engine. This
enables more fuel to be burnt with a greater mass of charge air, increasing
engine power output. Better air availability enhances better combustion,
thus leading to lower fuel consumption and less emission.

Exhaust gas Turbocharging

The advantage of modern turbocharged engine, over a naturally
aspirated engine of identical power output are as follows:
Lower fuel consumption
Lower emission
Better torque characteristics
Lower weight and a smaller engine package
Lower engine noise
Altitude compensation.
As a result, turbochargers contribute significantly to the protection of
the environment and the better utilisation of energy resources.

Construction and function of a Turbocharger

A Turbocharger consists of a compressor and a turbine connected

by a common shaft. Centrifugal compressors and centripetal
turbines are most popular types used in automotive applications and
form the basis for most turbochargers today.

Compressor housing
Back plate
Central housing

Compressor wheel

Thrust plate

Turbine wheel assy.

Journals

Boost pressure pipe

Turbine housing assy.
Actuator assy.

Bearing System

The turbocharger shaft and turbine wheel assembly rotates at

speeds up to 300,000 rpm. Only sleeve bearings specially
designed for turbochargers can meet these high requirements at
a reasonable cost.
Radial bearing system
Axial thrust bearing system
Oil feed
Oil drain
Sealing
Heat shield

Control system or Waste-gate Actuator

To meet the demands of the engine at low speeds, full boost

pressure should be available. At the same time, at high speeds,
this boost pressure needs to be controlled to achieve the required
engine performance.

Compressor
Wheel

Turbine Wheel

By-pass passage
Actuator assy.

RECOMMENDATION FOR OPERATION AND

MAINTENANCE
The engine manufacturers recommendations for operation and
maintenance shall be authoritative for the operation of turbocharged
engines. Special attention should be paid to:

Operation Recommendations

Engine should not be put under full load immediately after start.
We recommend the engine to be run at idling speed for a short
time (min. 60 seconds). Warm up the engine under medium speed
and then load.
After the engine has been operating at full load for a longer
period of time, we recommend a short idling time before
switching off (min 60 seconds).

Maintenance Recommendations

Turbochargers and boost pressure control valves do

not require any maintenance.

Engine oil has to be changed regularly in accordance

with the engine manufacturers instructions.

Maintenance work has to be carried out regularly on

the oil filter and air filter systems, in accordance with
the engine manufacturers instructions.

Checks have to be made on the oil, air and exhaust

piping, as well as, on all other connections and seals,
to ensure that they are tight and no damage has
occurred.

Maintenance Recommendations

When carrying out maintenance work on the engine

(e.g. adjusting engine valves), in most of the cases, the
piping leading from or to the turbocharger must be
removed. Close the piping openings on the
turbocharger.

When fitting the turbocharger to the engine, fill the

central housing with clean oil and before fitting make
absolutely sure that all piping connected to the
turbocharger is cleaned thoroughly.

If this advice is followed, a turbocharged engine

has, from our experiences the same life span as a
naturally aspirated engine.

USEFUL TIPS

Turbocharger is matched with a particular engine in

association with the engine manufacturer. Therefore,
the specification stipulated by the engine manufacturer
should not be changed

Changes in boost pressure control of the turbocharger

(where applicable) may result in engine damage.

Use only the air filter recommended by the engine

manufacturer and do not change the pipe connections to
the turbocharger and from the turbocharger to the
engine.

USEFUL TIPS

Use only the oil filter and oil grade recommended by

the engine manufacturer.

Use only the charge air cooler (where applicable)

recommended by the engine manufacturer.

Changes in the exhaust system are not recommended.

Ensure proper functioning of exhaust brake, if fitted.

Use original gaskets and connecting pipes

DOS AND DONTS FOR SATISFACTORY

FUNCTIONING OF TURBOCHARGER
DOS

Regular change of engine oil/oil filters according to engine

manufacturers specification.

Regular change/cleaning of air filter element according to engine

manufacturers specification.

Check for oil pressure at engine idling condition. Minimum oil

pressure to be as per engine manufacturers recommendation during
idling.

Idle the engine for 60 seconds after starting the engine.

Idle the engine for 60 seconds before switching off the engine.

Periodic cleaning of crankcase breather is necessary to allow free

flow of oil from turbocharger outlet.

Regularly check all air, oil and exhaust connections for leaks and
abnormal dust/oil carbon build up.

DOS AND DONTS FOR SATISFACTORY

FUNCTIONING OF TURBOCHARGER
DONTS

Dont run the engine with low oil pressure.

Dont put the engine under full load immediately after starting.

Dont switch off the engine under full load.

Dont run the engine with damaged oil feed & drain pipes.

Dont run with damaged/faulty connections from the air

cleaner to the turbocharger and turbocharger to the inlet
manifold.

Dont run with damaged/faulty connections to the turbocharger

turbine inlet and from turbine outlet.

Dont use the control valve for lifting the turbocharger.

TURBOCHARGER
IDENDIFICATION
M &M
Model
Part number
NEF 3800 TCI 2.6Litre
0024026
XD3P TCI 2.5Litre
03130G0071N
NEF 3200 TCI 2.6 Litre LCV BSII 0305GC0030N
NEF 3150 TCI 3.2 Litre LCV BSII 0305GC0051N
NEF 3800 TCI 2.49 Litre
0305GC0041N
MDI 3200 TC BSII 2.5 Litre
0305GB0021N
EUV 3800 TCI CRDi - 2.6 litre 0305GC0021N

Turbocharger
part number
5304 970 0027
5304 970 0031
5304 970 0038
5304 970 0042
5303 970 0091
5303 970 0095
5303 970 0088

Excessive Engine Oil Consumption

Clogged Air Filter Element.

Turbocharger damaged (Compressor Side).
Restriction in air intake duct to Compressor inlet.
Air Leak in duct between Compressor and Intake
manifold.
Air Leak between Intake manifold and cylinder head.
Restriction in turbocharger oil drain line.
Restricted engine crank case breather.
Restriction in Oil separator hose (tappet cover) and (Air
filter inlet hose).
Worn-out valves, piston rings, liners, internal engine
problems (increased blow by)

Oil Leak From Compressor

Clogged Air Filter Element.

Turbocharger damaged (Compressor Side).
Restriction in air intake duct to Compressor inlet.
Restricted exhaust system.
Restriction in turbocharger oil drain line.
Restricted engine crank case breather.
Restriction in Oil separator hose (tappet cover) and (Air
filter inlet hose).
Worn-out valves, piston rings, liners, internal engine
problems (increased blow by)

Oil Leak From Turbine

Restriction in turbocharger oil drain line.

Restricted engine crank case breather.
Worn-out valves, piston rings, liners, internal engine
problems (increased blow by)
Turbocharger damaged.

Noise From Turbocharger or Engine

Restrictions in air intake duct to compressor inlet.

Restriction in air outlet ducts from compressor outlet to
intake manifold.
Restriction in intake manifold.
Air leak in duct between air cleaner and compressor.
Air leak in ducts between compressor & Intake manifold.
Air leak between intake manifold & cylinder head.
Gas leak between exhaust manifold & cylinder head.
Turbocharger damage.

Oil carry over

will result if prolonged operation in
High Speed and low load
High idling ( A/C on condition)
High crank case
pressure drop due to choked breather
T/C oil not draining properly
Air leak in compressor outlet
Excessive pr drop due to a choked air cleaner
( Short operation in the above modes are not critical )

Check the compressor wheel for damage.

Damaged

Replace TC

Not Damaged

Check the compressor wheel / turbine wheel for

rubbing with housing.

Rubbed
Replace TC

Not rubbed

Not free
Check the shaft rotation; rotation should be free.

Replace TC

Rotation free

Check the rotor assy. play; press the shaft outward

and rotate the shaft, the wheel should rotate freely.

Wheel gets struck

Wheel does not get struck

TC can be reused. Check other parameters for complaint

Replace TC

FAILURE MODES
Due to dust entry into compressor housing,
compressor wheel blades were got eroded / worn-out at entry area.

FAILURE MODES
DUE TO FOREIGN PARTICLE ENTRY

Probable causes : Lose washer / nut / bolt / screws or any lose particle entry into
compressor inlet.

FAILURE MODES
DUE TO FOREIGN PARTICLE ENTRY

Probable causes : Lose washer / nut / bolt / screws, broken valve seat / guides,
core sand particles, piston seizure or any lose particle entry into turbine.

FAILURE MODES
Oil starvation (Seizure symptoms and blue color formation indicate
overheating.).

Probable causes : No oil supply to the turbocharger. Oil pump failure, blockage in the
oil supply pipe.

FAILURE MODES
DUE TO LACK OF OIL, Overheating symptoms observed
predominantly at turbine side only.

Probable causes : Inadequate oil supply to the turbocharger. Low oil pressure,oil leakage
in the oil circuit, restriction in the oil supply pipe (gasket sealent, smaller size banjos,
wrong size / damaged pipe), low oil level in the sump.

FAILURE MODES
DUE TO DIRT IN OIL

Probable causes : Turbine shaft, Journal wornout excessively due to bad oil condition (foreign
particle in oil).

FAILURE MODES
Gasket sealant application at oil Outlet flange

Probable causes : Excessive gasket sealant application at oil outlet flange will result in
restriction in oil drain leading to oil leak into compressor and turbine housing.

TEL Contact List

DELHI

KOLKATA

A B DUBEY

P BATTACHARJEE

011 - 28341652, 28343149

033 - 25783318, 25782584

98100 19912

98300 28205

PUNE

CHENNAI

ASHOK KUMAR YADAV

R D PRASAD

020 - 22932538

044 - 24318820, 24318821

98223 07667

98410 77076

THANK YOU