INSTALLATION DATA AND DETAILS

(Some installation data mentioned can be ignored for truck- and tractorpulling applications, like remarks made on air intake and exhaust systems)

The air filter must remove particles greater than 5μm at an efficiency of 95% and be of sufficient capacity to match the air consumption of the engine. Recommended filters should always be used with a pressure drop indicator. Intake systems must be capable of withstanding depressions up to 0.07 bar (1.0 psi).

Hose and clip connections of intake manifold systems must be capable of withstanding the turbocharger pressure ratio. V-band clamps connections are preferred and must be used above 3:1 pressure ratio.

Exhaust systems must be capable of operating at exhaust back pressures of up to 0.1 bar (1.5 psi). This limit is increased to 0.14 bar (2 psi) if a catalytic converter is fitted. Exhaust brake applications are permitted to impose 4.5 bar (65.3 psi) back pressure.

Oil should be filtered to 10μm with efficiency of 60% TWA (Time Weighted Average) /20 μm with efficiency of 85% TWA. Efficiency assessed using ISO Standard 4572/SAE J 1858.

The oil quality must be as specified by the engine manufacturer and will be a minimum API SE – CD (MIL - L - 2104C) specification. Improved life can be obtained by using super high performance diesel (SHPD) oils, particularly in industrial applications which use extended oil drain periods.

Normal oil temperature is 95+/-5°C (203+/-9° F). It should not exceed 120°C (248°F) under any operating condition.

Any pre-lube oil must be clean and preferably be identical to the oil used for the engine.

The orientation of turbine housing, bearing housing and compressor cover must be reset  according to the application. During installation, do not attempt to rotate these components. If an installed angle is necessary, oil inlet centre-line must be +/- 10 degrees from vertical and rotor centre-line +/- 5 degrees from horizontal.

Oil return pipes are permitted to decline at an overall angle of not less than 30 degrees below horizontal.

All turbocharger applications require a drain pipe of internal diameter greater than 19 mm which has integrated connectors. To ensure oil returns into the engine under all operating conditions, the return connection into the engine sump must not be submerged and the outlet flange of the turbocharger must be 50 mm above the maximum oil level of the engine sump pan. Crankcase pressure should be limited ideally to 0.01 bar (0.12 psi) but 0.02 bar (0.2 psi) can be accepted.

Oil pressure of 1.5 bar (20 psi) must show at the oil inlet within 3 - 4 seconds of engine firing to prevent damage to turbocharger bearing system. A flexible supply pipe is recommended. Minimum inlet diameter is 6 mm.

The minimum oil pressure when the engine is on load must be 2.1 bar (30 psi). Maximum permissible operating pressure is 4 bar (58 psi) although 6 bar (88 psi) is permitted during cold start up. Under idling conditions pressure should not fall below 0.7 bar (10 psi).

Recommended oil flows for the turbochargers are 3 liter/min at idle and 3.5 - 4.5 liter/min above maximum torque speed.

Never use liquid gasket substances or thread sealant as any excess can enter the turbocharger oil system to obstruct flow and cause fatal damage to your turbocharger.

Recommended coolant flows for the turbochargers are 3 liter/min at idle and 10 - 14 liter/min above maximum torque speed.