Turbocharger User’s Manual

Turbocharger User’s Manual

1. Working Principle

The turbocharger uses the exhaust air of an engine to drive a turbine. The running turbine drives a high-speed air-compressing impeller. The compressed fresh air is aspirated into the cylinders of the engine to increase the air-fuel ratio. This improves fuel combustion efficiency, decreases fuel consumption, and increases engine power. At the same time, emissions of CO, HC, NOX, and PM are reduced.

In high-altitude areas, lower air pressure reduces engine power. A turbocharged engine can compensate for power loss caused by insufficient air (altitude up to 2500 meters).

2. Inspection Items Before Mounting

2.1 Inspect the Turbocharger

1. Check whether the turbocharger matches the engine.
2. Check for damage during transportation.
3. Manually rotate the shaft & turbine to ensure it runs freely and does not scrape the housing.

2.2 Inspect the Air-In and Air-Out Tubes

1. Ensure the air filter element is clean; a dirty filter may cause turbocharger leakage or damage.
2. Check for particles in the compressor air-in tube and engine air-out tube to prevent wheel damage.

2.3 Inspect the Oil-In and Oil-Out Tubes

1. Replace the oil filter and fill the new element with lubricating oil.
2. Ensure oil-in and oil-out tubes are clean, untwisted, and not blocked.
3. Replace sealing washers on oil-in and oil-out flanges if eroded or distorted.
4. Replace lubricating oil if dirty or deteriorated. Change oil while engine is hot to prevent contamination at the engine bottom. Use an oil filter to ensure particle size does not exceed 20µm. Follow engine manufacturer’s recommendations; if none, use 15W-40 CD or higher. Do not mix different oil types.

3. Mounting Requirements

1. Fix the turbine housing air-in flannel to the engine air-out tube using an elastic expansion connector to prevent distortion and overheating. Heavy tubes must have additional support. Pre-lubricate and ensure oil cleanliness during assembly.
2. The oil outlet on the bearing housing must face downward and not exceed 23° from vertical.
3. The oil-in tube should be as short as possible to reduce oil supply delay. Oil pressure should display within 3–4 seconds after engine start to protect bearings from short lubrication.
4. The oil-in tube diameter must be ≥9.5mm and oil-out tube ≤30mm. The oil-out outlet must be higher than the maximum lubrication oil level at the engine bottom and free from distortion.
5. Use a paper filter for the compressor inlet to prevent power loss from oil contamination. Maximum filter pressure difference: 6 KPa.
6. Turbine air-out backpressure should not exceed 6 KPa. Refer to the engine usage manual for details.