We’ve recently received a KBB HRPR4000 Turbocharger for inspection following a failure, and we wanted to share a quick update on our findings and suggested next steps.
Upon dismantling, we discovered significant damage:
- The rear seal plate was severely damaged, with material missing and protruding into the turbine area.
- The compressor wheel had also been forced against the air inlet housing, damaging both the wheel and the diffuser.
- Further inspection revealed the turbine wheel was missing its sealing ring, and the rear backplate had material ground into it, resulting in extreme heat and a cracked turbine wheel.
- We also noted heat damage to the thrust bearing, thrust collar, inner bearing housing, and the turbine-end bearing.
While some of the components are beyond repair, others can be salvaged, and we’ve put together a cost-effective plan:
- Replace the core assembly (cartridge)
- Repair the air inlet and outlet casings
- Drill out and renew sheared studs
- Polish the diffuser
This approach offers two major benefits:
- Faster turnaround – a new turbocharger has a 12 -14 month lead time, but we can have the cartridge with us in just 10 days.
- Significant cost saving – this repair will save the operator over £20,000 compared to a full replacement.
