Bad Turbo Putting Oil in the Air Tanks: Causes, Consequences, and Solutions

[MikePhua]

When it comes to maintaining heavy equipment, few issues can be as concerning and troublesome as finding oil in the air tanks. One of the common culprits behind this problem is a faulty turbocharger. The turbo plays a vital role in engine performance by compressing the air entering the engine, which boosts power. However, when the turbo begins to fail, it can cause oil to leak into the air intake system, eventually ending up in the air tanks.
In this article, we will explore the causes and consequences of a bad turbocharger putting oil in the air tanks, the steps to diagnose the issue, and the solutions that can help prevent further damage to the engine and air system.
What Is a Turbocharger and How Does It Work?
A turbocharger, commonly referred to as a "turbo," is a device that increases the efficiency and power output of an engine. It works by forcing additional air into the engine’s combustion chamber, allowing it to burn more fuel and thus produce more power. A turbo uses exhaust gases to spin a turbine, which in turn drives a compressor that pushes more air into the engine.
While the turbocharger significantly enhances engine performance, it also comes with potential risks. If the turbo fails, oil can leak into the intake system, leading to a series of complications that may compromise the engine's performance and the functionality of other components, like the air tanks.
The Role of the Air Tanks in Heavy Equipment
Air tanks, often referred to as air reservoirs or air receivers, are an essential part of the air brake system and other pneumatic systems in heavy equipment. These tanks store compressed air, which is used for various functions, including operating the brakes, powering tools, and activating certain engine components.
When oil contaminates the air tanks, it can cause serious issues. Oil in the air system can damage the air compressor, clog filters, affect the operation of pneumatic tools, and reduce the overall efficiency of the equipment.
How Does a Bad Turbo Put Oil in the Air Tanks?
A faulty turbocharger can put oil into the air intake system in several ways, but the most common is through a worn or damaged seal. The turbo relies on seals to keep oil and air separated. When these seals wear out, oil from the turbo’s bearing chamber can leak into the compressor side of the turbo, which is connected to the air intake system. As the air passes through the intake, it carries the oil with it, leading to contamination of the air tanks.
Several signs indicate that a bad turbo might be the cause of oil entering the air tanks:

1. Excessive Smoke
   One of the first signs of a failing turbo is excessive smoke coming from the exhaust. If oil is leaking into the intake, it will be burned during combustion, resulting in a blue or gray exhaust smoke.
   
2. Loss of Power or Poor Performance
   A bad turbo can lead to a loss of power or decreased engine performance. Since the turbo is responsible for forcing air into the engine, a malfunction can cause insufficient air intake, reducing the engine's efficiency.
   
3. Oil Contamination in the Air System
   If oil is visible in the air tanks, hoses, or air filters, it’s a clear indication that the turbocharger is leaking oil into the intake system.
   
4. Hissing or Whining Noise
   A failing turbo can sometimes cause a whining or hissing noise, especially when accelerating. This sound is a result of air and oil leaking from the turbocharger.
   

Consequences of Oil in the Air Tanks
Oil contamination in the air tanks can lead to a number of issues that affect the overall performance of the equipment:

1. Damage to the Air Compressor
   The oil can contaminate the air compressor, causing it to overheat and fail. The compressor relies on clean, dry air to function properly, and oil contamination can cause the compressor’s seals to fail or clog internal components.
   
2. Clogged Air Filters
   Oil in the air system can clog air filters, reducing their effectiveness. When the filters are clogged, they can no longer properly clean the air, leading to dirt and debris entering the engine and causing further wear.
   
3. Reduced Brake Performance
   In equipment with air brake systems, oil contamination can lead to reduced braking efficiency. The oil can compromise the seals and valves in the braking system, potentially leading to brake failure or reduced stopping power.
   
4. Increased Maintenance Costs
   If oil is allowed to contaminate the air system and air tanks, it can lead to expensive repairs. The longer the problem goes unresolved, the more damage it can cause to the engine, turbo, air tanks, and other components, ultimately increasing the cost of repairs and maintenance.
   

Diagnosing and Fixing the Issue
If you suspect that a bad turbo is putting oil in the air tanks, the first step is to perform a thorough inspection. Here are the key steps to diagnosing and addressing the issue:

1. Check the Turbocharger for Damage
   Inspect the turbocharger for visible signs of damage, such as oil leaks, worn seals, or excessive play in the turbine shaft. If you notice any issues, it’s likely that the turbo needs to be replaced or repaired.
   
2. Inspect the Air System
   Check the air intake hoses, air filters, and air tanks for signs of oil contamination. If oil is found, it’s a clear indication that the turbo is leaking oil into the system.
   
3. Test the Turbo’s Performance
   If you're unsure whether the turbo is the cause of the issue, consider performing a turbo boost pressure test. This test can help determine if the turbo is producing the correct amount of air pressure and identify any issues with the turbo’s performance.
   
4. Replace the Faulty Turbo
   If the turbo is determined to be the cause of the problem, it will need to be replaced. This is a relatively complex repair that may require the expertise of a mechanic familiar with turbochargers. Make sure to replace the turbo with one that matches the specifications of the original part.
   
5. Clean the Air System
   After replacing the turbo, clean the entire air intake system, including the hoses, filters, and air tanks. This will remove any residual oil and prevent further contamination. Consider replacing the air filters, as oil contamination may have caused them to lose their effectiveness.
   

Preventing Turbo Issues and Air Tank Contamination
To prevent issues like oil contamination in the air tanks, regular maintenance of the turbocharger and air system is crucial:

1. Regular Turbo Inspections
   Periodically inspect the turbo for signs of wear and tear. Check for any leaks, unusual noise, or performance issues that might indicate a problem.
   
2. Maintain Clean Air Filters
   Ensure that air filters are regularly cleaned or replaced. Dirty filters can exacerbate turbocharger wear and increase the chances of oil contamination.
   
3. Monitor Engine Performance
   Pay attention to changes in engine performance, such as power loss or excessive smoke. Early detection of a turbo issue can prevent more extensive damage.
   
4. Use High-Quality Oil
   Always use high-quality oil in your turbocharger to prevent premature wear. Follow the manufacturer's recommendations for oil type and change intervals.
   

Conclusion: The Importance of Addressing Turbo Problems Early
A bad turbo putting oil in the air tanks is a serious issue that can lead to significant damage and costly repairs if not addressed promptly. Regular maintenance and inspections are key to ensuring that the turbocharger and air system remain in good working order. By staying vigilant and addressing any signs of turbo failure early, you can prevent further damage to the equipment and keep it running smoothly.
In the world of heavy machinery, where downtime can be costly, proactive maintenance is essential for preventing small issues from turning into expensive repairs.