TURBOCHARGER BASIC KNOWLEDGE:

Turbocharger is the important part for improving the performance of engine and reducing the exhaust gas. It is not a power source but works with the remaining energy of engine exhaust. It is used to supply more compressed air to the engine.

The turbocharger is installed on the vent-pipe of engine. The exhaust gas from cylinder boosts the turbine impeller whose running then drives the compressor impeller and push the compressed air filtered by air filter to the cylinder. With more and more compressed air entering the cylinder, the increased fuel allows more sufficient burning. As a result, the performance of the engine is enchanced and the exhaust gas is reduced. The turbocharger can also help to retrieve the engine efficiency under low pressure environment in altiplano.

The side-valve turbocharger has the advantage of low-speed, high-torque and the performance of high/low speed. The side valve is used to control the boosting pressure, which, when higher than a scheduled value, the side valve begin working. Then some of exhaust gas is let out directly. So the boosting pressure ratio is under control and the outburst pressure of the cylinder would not exceed the allowable value of the engine¡¯s mechanical load. It helps the engine to work smoothly and long life use.

THE INSTALLATION INSTRUCTION AND ATTENTION:

1.       Do not check the turbocharger until the engine has been cooled down completely. To avoid personal injury, do not start the engine when checking.

2.       Avoid any object into the turbocharger or the engine¡¯s inlet/outet system when install/uninstall the turbocharger.

3.       When installation, follow strictly the instruction. Renew the sealing parts at oil inlet/outlet and the turbin¡¯s air inlet/outlet at the same time to ensure good sealing condition.

4.       It is very important to maintain good lubricating to the turbocharger. The turbocharer is lubricated by the clean pressed oil from the engine¡¯s lubricating system. It has separated inlet pipe connected with turbocharer oil inlet. The lubricating oil passing onto the turbocharger will go back to the engine under gravity through outet pipe.

5.       For turbocharger of newly installed or long stayed, some lubricating oil should be applied at the inlet and then drive the impeller manually, so the oil can cover the whole bearing surface.

6.       Use the lubricated oil specified and oil filter recommended by the engine manufacturer according to engine manual instruction.

7.       Check the oil pipe regularly to ensure the smooth flow.

8.       Keep the crankshaft case breathing system smooth to avoid too much pressure inside which may cause slow oil flow and oil leakage.

9.       Keep the pipes between air filter and compressor, compressor and engine inlet, turbocharger and engine outlet good tight and seal. Otherwise it may cause noise and oil leakage.

10.   Check the air filter regularly. Clean and change the filter core in time to avoid compressor oil leakage.

11.   Start the engine, keep it running 3-5 minutes in idling speed before accelerating, so the good lubrication could be assured. Pay attention to controlling the time of idle running, otherwise it may cause turbocharger oil leakage.

12.   Do not turn off the engine immediately when stopping. Keep it running for 3-5 ninutes at iding speed. Wait until the temperature and running speed of turbocharger drop down, so as to prevent the inner burning, bearing damage, etc.

13.   For side-value turbocharger, never take the valve pole as handle, which may affect the sensitivity of the implement of the valve.

FAULT DIAGNOSIS

Do not disassemble the turbocharger immediately when you meet problems and doubt possible fault during using. You should first check the Fault Diagnosis Sheet. Only after making sure that the problem has to be solved by disassmebling the turbocharger, you may go on for further checking. Experience shows most faults of turbocharger are associated with improper using. Only changing the turbocharger in spite of invesgating the real problem, or fix the problem by simply change the turbocharger, may cause mew problem or extra loss.

Waring: before fixing the reason of damage, do not replace new turbocharger. Follow the requirement below to change the turbocharger when it is necessary:

CLEAN:

1.       Drain the dirty lubricating oil of engine.

2.       Remove the oil pan and clean. Then install it in the engine.

3.       Remove the turbocharger¡¯s inlet and outlet pipe. Clean inside pipe and then fix it to the engin.

4.       Fill with filtered new lubricating oil specified by engine¡¯s manufacturer. to ensure the lubricating oil which enter the turbocharger clean is the key to make the turbocharger long life use.

5.       recommended by engine¡¯s manufacturer, the oil filter and air filter should be replaced. The lubricating oil, the oil filter and air filter must be in engine¡¯s manufacturer¡¯s recommendation range. The wrong products may damage the turbocharger and engine.

INSTALLATION

6.       Pour clean lubricating oil to the inlet of the turbocharger as pre-lubricating

7.       when installing, replace all seals connected with turbocharger (free gasket is available in the package)

8.       Install turbocharger according to the procedure recommended by engine¡¯s factory or the procedure of final engine assemble.

9.       Prevent any foreign matter from entering the turbocharger and various pipes connected with it when replacing the turbocharger.

USE

10.   Start the engine, keep it run in low idling speed for a few minutes.

11.   Begin normal use

12.   Replace regularly the lubricating oil, oil filter and air filter according to engine manufacturer¡¯s requirement.