2.18.1 What to do and what not to do

What to do:

• Before assembling the turbocharger, make sure that the protection caps are fitted on all openings of the turbo.
• Ensure pre-lubrication of the turbocharger.
• Periodically check that the joints are sealed against oil and air.
• Use lubricating oil according to the specifications described in Par. 2.4.
• Check the engine oil level.
• Before switching it off after it has been used, make the engine run idle, or without a load, for approximately 1 minute.
• Ensure that controls and maintenance intervals of the engine are observed as specified in Tab. 2.8 and 2.9.
• Make sure that the engine and equipment are used correctly so as not to compromise the life of the turbocharger.

What not to do:

• Do not store turbocharges in damp, wet places if they are not in their original packaging.
• Do not expose the turbocharger to dust and dirt if it is not in its original packaging.
• Do not lift of hold the turbocharger from the actuator rod if it is not in its original packaging.
• Do not apply additives to the lubricating oil and fuel, unless instructed to do so by Kohler.
• Do not increase engine speed, or apply loads, immediately after start-up.
• Do not intervene on the actuator settings  A (Fig. 2.59).
• Do not let the vehicle / engine run at idle speed for more than 20-30 minutes at a time.

2.18.2 Practical operating rules

Users can help to maximise the duration of their turbocharger by following the rules described below.

1. Start-up
   Start the engine at idle speed, or without a load, for approximately one minute. Oil operating pressure is reached within a few seconds and enables the moving parts to warm up and be lubricated.
   Immediately increasing the engine speed upon start-up means making the turbocharger run at high speed with suboptimal lubrication, which may compromise the life of the turbocharger.
2. After maintenance or a new installation
   Proceed with pre-lubrication by filling new oil into the oil supply duct B until filling it completely. Start the engine at idle speed, or without a load, for a few minutes in order to ensure that the oil and bearings system operate satisfactorily.
3. Low temperature air or engine inactivity
   If the engine has been inactive for some time, or the air temperature is very low, start the engine at idle speed or without a load for a few minutes.
4. Engine shutdown
   Before switching the engine off after intense activity, one must allow the turbocharger to cool down. One must therefore let the engine run at idle speed or without a load for at least 2 minutes, thus allowing the turbocharger to cool.
5. Engine at idle speed
   Avoid using the engine at idle speed or without a load for long periods (more than 20-30 minutes). When operating at idle speed or without a load, the turbocharger is at low pressure in the exhaust chamber C and air supply D; this may cause oil leaks from seals E
   to the extremity of the shaft. Even if this does not cause damage, it can cause blue smoke from the exhaust when the engine speed and load are increased.

2.18.3 Before installing a new turbocharger

  Important

• Do not lift the turbocharger with one hand from the  box.
• Do not lift turbocharger from Comp hsg side.
• Lift the turbocharger with both hands from box.
• Make sure to use clean gloves.
• Handle the turbocharger as indicated in Par. 2.17.4.

1. Avoid lifting from the intake side G.
2. Remove cap guard F and check that there is no excessive shaft axial and radial clearances.

3. Check for any signs of friction of the turbine on the turbocharger body.
4. Check for any traces of oil leaks on the turbocharger body.
5. After having check everything, reapply cap F on intake opening H of the turbocharger and do not remove it until assembly has been completed.

6. Check the correct assembly of the capscrews and the presence of paint on them.

2.18.4 Installation instructions

1. Remove the cap guards with care only when assembling.
   Handle carefully avoiding erratic movements.

2.18.5 Replacement instructions

Always understand the cause of the breakage of the turbocharger before replacing it.
Correct the cause of the breakage before replacing it with a new turbocharger.
If in doubt, contact KOHLER service department.

  Important

• Failure to comply with these instructions can cause damage to the turbocharger and void the warranty.
• Modifying the calibration of the turbocharger damages the turbocharger/engine.
• Always use the correct gaskets, and fit carefully to avoid blocking holes when mounting.
• Refer to the manual of the engine / vehicle, for: the correct type and quantity of oil, the correct tightening of components, instructions and installation.
• It is forbidden to use liquid gaskets or sealants, particularly for the oil inlet/outlet.
• Avoid dirt / debris while installing the turbocharger.
• Before mounting the turbocharger, check that the code of the component is correct for the type of engine, as mounting the wrong turbocharger can damage the turbo / engine and void the warranty.