©O MITSUI-MAN B&W INSTRUCTION BOOK VOLUME 4 COMPONENT No. 2 FITTINGS AND ACCESSORIES Ssreaniastet ] MITSUI ENGINEERING & SHIPBUILDING CO.,LTD.This book must in no case be wholly or partially OQ copied and published or passed to unauthorized persons without the permission of MITSUI ENGINEER- ING & SHIPBUILDING CO., LID.OCHOYFHFGRONA0CHYFGLeDN COMPONENT NO.2 ( FITTING AND ACCESSORIES ) CONTENTS EXHAUST GAS TURBO-CHARGER ELECTRONIC HIGH SPEED TACHOMETER FOR TURBO-CHARGER CYLINDER LUBRICATOR AIR COOLER MAIN ENGINE TURNING GEARS MOTOR FOR TURNING GEAR STARTER FOR TURNING GEAR ROLLER CHAIN PRESSURE SWITCH AND TRANSMITTER LIMIT SWITCH OIL MIST DETECTOR THERMO SWITCH FOR FIRE DETECTOR AUX. BLOWER STARTER FOR AUX. BLOWER FUEL OIL 2ND STRAINER LUBRICATION OIL STRAINER FOR TURBOCHARGER NON-FLOW SWITCH FOR PISTON COOLING OIL INSTRUCTION MANUAL FOR GEISLINGER DAMPER AXIAL VIBRATION MONITOR ALPHA LUBRICATOR SYSTEM INSTRUCTION MANUAL OPERATION ALPHA LUBRIGATOR SYSTEM INSTRUCTION MANUAL MAINTENANCE INTERCONNECTION DIAGRAMS & ADDITIONAL COMPONENTS PUMP STATION FOR ALPHA LUBRICATOR SYSTEM« oD M.V. APL HAMBURG TURBOCHARGER’S NAME PLATE DETAILS MAIN ENGINE: ME #1 THI, Japan under license from ABB Turbo Systems LTD. ‘Type: TPL85 - B15 Serial No. : 208404 Timex: 196 per Sec Memax: 187 per Sec tumar: 550 °C temas: 520°C Wt 10700 kg ME #2 THI, Japan under license from ABB Turbo Systems LTD, ‘Type: TPL8S - B15 Serial No. : 208405 Tmax: 196 perSec Menax: 187 per Sec thinas: 850 °C temax’ 820°C ‘Wt 10700 kg ME #3 THI, Japan under license from ABB Turbo Systems LTD. Type: TPL8S - B18 Serial No. : 208406 Tumse: 196 pet SC Monae: 187 per Sec thine 850 °C tenae 520°C We 10700 kg AUXILIARY ENGINES: AE #1 ‘ABB Turbo Systems Ltd. ‘Type: TPL6S-A30 ‘Spec: Serial No: HT492982 Thine : 487 pet SC Mam: 468 per Sec thimax: 680 °C tomat? 650 °C We 885 kg AE #2 ‘ABB Turbo Systems Ltd ‘Type: TPLE5-A30 Spec: Serial No: HT492983 Maines 487 per Sec Nenax 468 per Sec tuanae: 680 °C tenet 650°C We 885 kg AE #3. ‘ABB Turbo Systems Lid. ‘Type: TPLES-A30 Spec: Serial No: HT492984 Rimes 487 per Sec Nena: 468 per Sec ‘hiya: 680 °C toma: 650°C Wt 885 kg AE #4 ‘ABB Turbo Systems Lid ‘Type: TPLE5-A30 Spec: Serial No: HT492985 Pune! 487 per Sec Nenae: 468 per Sec {Yaya 680 °C tema: 650°C Wt 885 kgMLV. APL ROTTERDAM TURBOCHARGER’S NAME PLATE DETAILS MAIN ENGINE: Ill, Japan under license from ABB Turbo Systems LTD. ‘Type: TPL8S - B15 HT: 208091 ME #1 | nn: 198 per'See Mana: 187 per Sec tuimas: 850 °C tena 520°C We'10700 kg 36 TAT, Japan under leense from ABB Turbo Systems LTD. ‘Type: TPL8S - B15 HT: 208092 Tumax: 198 per Sec Mona: 187 per Sec ME #2 | timex: 550°C tamax: 520°C We 10700 kg 36 ( ) THi, Japan under leense from ABB Turbo Systems LTD, Type: TPL8S - B16 HT: 208093 Taina 196 pet S€C Mane: 187 per Sec ME #3 | tune 850°C tenar’ 520°C We 10700 kg 36 AUXILIARY ENGINES: ‘ABB Turbo Systems Lid Type: TPLES-A30 HT: 482620 AE #1 — | tmx: 487 per Sec Nom: 463 per Sec timex: 680 °C tomar. 650°C WE 885 kg 36.50 50 ‘ABB Turbo Systems Lid Type: TPL65-A30 HT: 482621 AE #2 | car: 487 perSec Mana: 463 per Sec tuimax 680 °C tanec: 650°C ‘Wr 885 kg 3550 50 ‘ABB Turbo Systems Ltd Type: TPL65-A30 HT: 482623 AE #3 | imac: 487 per Sec Mona: 463 per Sec {imax 680 °C tema 650°C ‘Wr: 885 kg 35 5050 ‘ABB Turbo Systems Lid Type: TPLE5-A30 HT: 482824 AE #4 | nino: 487 per'Sec Nena: 463 per See {amps 680 °C tomar: 650°C : We 885 kg 35 50 50MSR JOB NO. 515174 Ie # DATE BY APPR, (TE3D29) _| PURCHASER a OE KOYO DOCKYARD S.No.2241 Ee me MES Fiat MSR BE!) 2 SYSTEM & = ALPHA LUBRICATOR FOR MITSUL-MAN B&W DIESEL ENGINE ( 11K98MC TYPE ) TLE z 7 TEST DOCUMENT | & SETUP DATA ELECTRONIC DEVICES & CONTROL SYSTENS DV. DESIGNING DEFT, MITSUI ZOSEN SYSTEMS RESEARCH INC. | LAF LES | Btyya-yaleee Reteh APPROVED a 8 VC Pespaah” | CHECKED ® MEDAZE. | DESIGNED BY -7— eel 7 te DATE & # A 12 Dec., 2007 DRAWINGNO, [RE KOY2241-AL-008KSetting of dip switches for MCU/BCU cu sw3 MCU Sw3 ON [sw3.1-8 [Not use 12345678 isw3.7 [Trigger system number = Bye single trigger system : ON ajololololo Muito tigger systems | OFF ‘OFF. [sw3.8 [NCU revision : FENCU revision C and ater + ON cu sw2 cu sw2 ‘ON [sw2.1-8 [Not use 123456728 siolo) ool ool ‘OFF wcu swt cu sw ‘ON, [SW141-2 [Bits Per Second at which the MCU communicates via 4 45678 la serial connection : Iswt.t OFF ‘SW12 OFF :38,4008PS} a alo|e|o|e swt OFF ‘SW12 ON +9,2008PS| ‘OFF. Iswi.1 ON. ‘SW12 OFF 9.6008} [swt ON. SW12 ON. 4,00BPs| [SWi3-8 [Not use ON [Cylinders number: 11 eylindors 12345678 | Switch position 3 OFF, 1,2,4: ON. wey ye) ye wl _{m| |mjm| | |sw2s |Bcu board revision: OFF Setting depends on ASD-board revision designation an) JAs0-0250-X ("X" indicates the revision) od 8: OFF binary value lone lubricator : ON [Two lubvicators : OFF Bcu swi Bou SW1 ‘ON ISW1.1-4 — [BCU Injection rate Sreviing 2345678 Switch position 3,4 OFF, 1,2: ON. = B] [@] | [Swiss Lowest injection rate olele| |e) Normally, the detection rate must be set 20 revi OFF. TIeeTtEw He binary value binary value Checked by: Date:Alpha lubricator test document Engine type: Plant spec. Nr: Engine builder: Engine numbe! Basic adjustments: MCU Sw Rev: BCU Sw Rev: LD option: Injection algorithm: Trigger system type: Feed rate at MCR: Rpm. MCR: Hydraulic delay: Number of strokes at MCR Alpha lubricator test document cneckes vy /7 (rcmell| 71KoEMC TESD29 Mitsui 97 5.18 External flag MEP Encoder A low 94 55 ims} aa To be fled in by engine builder Refering fo 100% oad and 100% feed rate sting | Refering 1o 100% load and 100% fee rate sting 9 yt: Programmed 3 Corrected 06 {deol [4 | _2072 EY s | 38 |v SEE | a1 | 3584 | 6 32.6 32. / 2) es 2] = 101.1 (eras 9 122.6 (22 4 | 1618 ELY 3 2045 || 264, 0. a | 2186 2/B. 10 | 2508 25S | | Injection offsot pater» 2/2/25)bricator constants: Lubricator piston diameter: Lubricator stroke: Number of pistons pr. lubricator Number of tubricatores pr. Cylinder Lubricator volumetric efficiency: Lubricator injection volume: Compensated for volumetric aficiancy 15.25 trom fmm] [Pcs] 087 2846 [emsistroke]Alpha lubricator test document Output Tes: MCU Solenoid outputs: Common alarm output: MCU Fail output: ‘BCU Fail output: Power fail MCU: Power fail BCU: BCU in ctrl. Output: Pump #1 start output: Pump #2 start output: HMI panel connections: ‘Slow down output: BCU Solenoid outputs: Digital Input Test: Mode Switch connections: Prejub input: An/AS input: MCU stop signal: BCU stop signal: LCD signal input: ‘Thermal cut out pump #1 input: ‘Thermal cut out pump #2 input: Checked by;| Checked: NUINUISIISINIS IN EERE NIN N IN Ginild Test 1 Test2 Test3 Test 4 Test 5 Test 6 Test 7 Test 8 Test 9 Test 10 Test 11 Test 12 Test 13 Test 14 Test 15 Test 16 Test 17 Test 18 Test 19 Test 20Alpha lubricator test document Analog Input Tes! Index signal input: ‘Temperatur signal input: Pressure signal input: Speed setting signal input: Tarcho Input Test: BCU pickup input: ‘Trigger/marker input: ‘Sw validation Feed rate at 100% Checked: x v Ks Test 21 Test 22 Test 23 Test 24 Test 25 Test 26 Test 27 Tost 28 Date:|tr hm remdon Ope Oe tor am [Ez] be serene tem fon Pst | Seon ano fT] te wnarovsom BD shetetnte FEE Mate Pune ee Vet 7 Uetea [Foust [TS] Pere aan asan 5S] toe TASES] nseptne TS) ae | Metetne FORS] sett (]__aitla zest Parone | pote Wise EJs es TRE]: moan PDmia = vn eterno ore Max mecharion dele Tacho Mods oo + beats Chew a0 © Teggesing cow ST Taner > : 5 oom | FS BT ow ae eee || cum, FB] BT oe 20 too FE on ume | OS BT oe Actuals jew | FOS | on eeoted fou | | Bw shes cam | (SB oe ‘lot en icon et oslo . ati setup | Tig (EE ten ren kasi —— 3 berate oneal tetas east con ‘Feed te seting maxim LCD fact | Meum ea Pos i vice [120 34 fares tea taro nse 3] evisian | Me tlie it ea eens | pecwmet acetate inner Slee Bam poeeed eciersowiiecin RS a Teotuteatincan eine pa© ShipPlantName=TE3D29 C NameOfEngineBuilder=Mitsui © EngineType=11K98MC C_NameOfCommissioner=MSR C_DateOfCommissioning=20071212 © EngineNo=( G_MCUVersion=1.67 C_Comment1=Loaded using LubSetup ver 1.29 C_Comment2=Drawing no. KOY2241-AL-008K ©.Comment3=Arranged by MSR C_Comment4=kKOY02241(TE3D28) C.Comment5=0 ©.TsampleLCDDetect=100 ©_OneLubOnEachGyl=-FALSE C_NoOFTestSequensPRELUBRICATIOI C-TestintorvalTimePRELUBRICATION=8 C.NoOfTestSequensTEST=1000 © TestintervalTimeTEST=8 C.CylinjectionOrderl C_CylInjectionOrder[1]}= © OylinjectionOrderl2-6 © CylinjectionOrder{3)= C.CylinjectionOrderl C_CyllnjectionOrder[5]-2 C_CylinjectionOrder{6]=7 C_CyllnjectionOrder{7]=9 ©.CylinjectionOrder{8}-0 ©.CyllnjectionOrder{9}=4 © CylInjectionOrder{10 C.CylinjectionOrder[11]-0 C.CylinjectionOrder{121 ©. CylinjectionOrder{13]=0 C IntervalZInjOffset=0 C.MinlndexLevel=—tt 26 CO. MaxindexLevel=38 135 © InjRateAlgorithm=mep C InjOffset{0]=279 C.InjOfset(1]=279 C ShaftTorsion[0]=0 © ShaftTorsion{1]=0 © ShaftTorsion[2]=0 © ShaftTorsion[3]=0 CC. ShaftTorsion[4]=0 © ShaftTorsion[5]=0 © ShaftTorsion[6]=0 C ShaftTorsion[7]=041 48. 49. 50, 51 52, 53. 54, 55. 56. 87. 58. 59, 60. 61. 62. 63. 64, 65. 66. 67. 68, 69, 70. n 72, 73. 74, 75, 76, 71. 78. 79, 80. ai. 82. 83. 84, 85, 86, 87. 88. 89, 90, 1 92, C ShaftTorsion{8]=0 C ShaftTorsion[9]=0 C ShaftTorsion[10]-0 C_ShaftTorsion[1 1]=0 C ShaftTorsion[12]=0 © ShaftTorsion{13]=0 C.InjTime=100 C Model CD=external flag C.IndexDevValueLCD=10 C.IndexDevTimeL GD=10 C HoldTimel CD=30 C_ModeMecDelay=ADAPTIV C Mecdelay[0]=0 C.MecdelayLt]=0 C Mecdelayl2]-0 C._Mecdelay[3]=0 C_Mecdelay[4]=0 C Mecdelayl5]=0 C_Mecdelay[6}=0 C Mecdelayl7]=0 C._Mecdelay[8)=0 C._Mecdelay[9]=0 © MecdelayL10]=0 C Mecdelay[t 1]=0 C Mecdelaylt2]=0 C.Mecdelayl13}=0 C Mecdelayl14]-0 C.Mecdelayl15]=0 C _Mecdelay[16]=0 C.Mecdelayl1 71-0 C_Mecdelayl18]=0 C._Mecdelayl19]=0 C_Mecdelay[20]=0 © Mecdelay[21]=0 C Mecdelayl22]-0 C Mecdelay[23-0 C Mecdelay[24]=0 C Mecdelay[25]=0 C Mecdelay[26]=0 © Mecdelay{27]-0 C OffsetMecDelay=11 C_MaxAngleDeviation=20 C.AliveFrequencyAlarm=30 C.AlarmDelay=10 © _OilTempHighAlarm=70 ©.OilPresLowAlarm=35 1093. 94. 95. 96. 97. 98. 99, 100. 101. 102, 103. 104 105. 106. 107. 108. 109. 110. 1 112, 113, 114, 115. 116. 117, 118. 119, 120. 121 122, 123, 124, 125. 126. 127. 128, 129, 130, 131. 132, 133, 134, 136, 136. 137. 138, (C_MaxPLubOil=100 C_MaxTOillntet=600 C_RPMMCR=940 C.NGyI=11 © RomRun=80 C.MinRpmAlarm=100 (©. MaxRamDeviationAlarm=100 C IndexLowAlarm=3 C_PumpIntervalTime=43200 C_PumpStopTime=60 © TrigPosCh1[0]=13 ©. TrigPosCht[1]=101 © TrigPosCht[2]=208 CTrigPosCh1[3]=269 OTrigPosCh1[4]=381 © TrigPosCh1[5]-502 © TrigPosChi[6]=542 © TrigPosChi[7]=657 C.TrigPosCh1[8]=766 © TrigPosCh1[9]-847 CTrigPosChilt (© TrigPosChiLt 1]=0 C_TrigPosChi[12]=0 C.TrigPosChi[t © TotalTrigch1=1024 © TrigPosCh2[0]-0 ©.TrigPosCh2[1]-0 C.TrigPosCh2[2]-0 ©. TrigPosCh2[3}-0 G TrigPosCh2[4]-0 © -TrigPosCh2[5]=0 C.TrigPosCh2{6]=0 © TrigPosCh2{7 © TrigPosChals] C TrigPosCh2t9. C TrigPosCh2[10]0 ©.TrigPosCh2{t 110 C TrigPosCh2[12]-0 C,TrigPosCh2{13]=0 © TotalTrigch2=0 ©.TrigSystemMode=angleencoder CMInj=469 © ModbusUnitNo=1 C_ModbusBaudRate=8600~ > © ModbusStopBit=1 © _ModbusParity=none "139. C_ModbusDataBit: 140. G_ModbusProtocol 141, C_Modbusinterfac 142, C_ModbusHandshak: 143, C.InjectionAngle{0]=0 144, C JnjectionAnglel 145, CG InjectionAngle[2]-0 146. C_InjectionAnelel. 147. G InjectionAngie[4]-0 148. C_InjectionAngle[5]=0 149, CInjectionAngle[6]=0 150. C InjectionAnglel 151, C.InjectionAngle[8]=0 152, C.InjectionAngle[9-0 153. CInjectionAnglel10]=0 154, C InjectionAngleL11 155. CG InjectionAnglel12]=0 156. CG InjectionAnale[ 131 187, ©. TDCMarkeri Offset=0 158. C.TDCMarker20ffset=0 159. G_TDCMarker30ffset=0 160. C_TDCTrigger Offset=0 161. C_TDCTrigger20ffset=0 162. C_PumpMode=automatic 163. C_DefaultPump=p1 164. CUntimedMinFeedRate=150 i 165. — C_LubSetupVersion=$ProjectRevision: 1.29 $ 168. C FeedRateSettingMin=40 167. C_FeedRateSettingMax=200 i 168. C.LODFactor=125 169. CG FeedRateSettingMaxNormalService=120 170. C.NormalMax=150 171. C.MScuffing=200 172, AbsoluteMin: 173. C_MEPRelativeLimit=63 174. C_POWERRelativel imit=40 175. C.TotalLubInjVolume=0 178, C.TelegraphSignalScale=200 1 12‘APL ROTTERDAM NEW SW VERS. 1.77 091020.txt E3029 _ShipPlantName: C_NameOfengineBuilder=Mitsui _EngineType=11K98MC C_DateOfCommissioning=20071212 C_EngineNo=0 CMcuversion=1.77 C_Comment1=Loaded using LubSetup ver 1.29. Change of sw 091010 to 1.38/1.77 C_Comment2=Drawing no.: KOY2241-AL-08K C_Comment3=Arranged by MSR C_Comment4=KOYO2241(TE3D29) C_Comment5=0 C_TsampleLCDDetect=100 C_OneLubOnEachCyl-FALSE C_NoOfTestSequensPRELUBRICATION C TestintervalTimePRELUBRICATION=8 C_NoOfTestSequensTEST=1000 C_TestintervalTimeTEST=8 €_CylinjectionOrder(0) C_CylinjectionOrder[1]=2 €_CylinjectionOrder{2) €_CylinjectionOrdert3} €_CylinjectionOrder(4 €_CylinjectionOrder{5 _CylinjectionOrder{6]=7 C_CylinjectionOrder{7 €_CylinjectionOrder{s)= C_CylinjectionOrder{9) €_CylinjectionOrder{10}=10 C_CylinjectionOrder{11]=0 C_CylinjectionOrder{12]=0 C_CylinjectionOrder{13]=0 C_Interval2injoffset=0 C_Minindextevel=-20 C_MaxindexLevel=135 C_InjRatedlgorithm=power C_Injofrset( _ShaftTorsion{0]=0 C_ShaftTorsion{9]=« _ShaftTorsion{10]=0 C_ShaftTorsion[11]}=0 C ShaftTorsion{12]=0 €_ShaftTorsion{13]-0 C_Anjrime=100 C_ModeLCD=external_flag C_IndexDevValueLCD=10 C_IndexDevTimeLCt C_HoldTimeLCD=30 Page 1‘APL ROTTERDAM NEW SW VERS, 1.77 091010.txt : ¢_ModeMecDelay-adaptiv C_Mecdelay(01=0 _Mecdelay{t]=0 C_Mecdelay{2}-0 C_Mecdelay{3]=0 C_Mecdelayl4]=0 C_Mecdelay(5}=0 C_Mecdelay{6]-0 C_Mecdelay{7}=0 C_Mecdelay{8]=0 C_Mecdelayi9]=0 C_Mecdelay{14]=0 C_Mecdelay{15} ! C_Mecdelay{16]=( C_Mecdelay(17}=0 C_Mecdelay[18]=0 C_Mecdelay{19]=0 C_Mecdelay{20} C_Mecdelayi21]=0 C_Mecdelayi22} C_Mecdelayi23}=0 C_Mecdelayi24]=0 C_Mecdelay[25]=0 C_Mecdelay[26]-0 C_Mecdelayl27]-0 C_OffsetMecDelay=11 C_MaxAngleDeviation C-AliveFrequencyAlari C_AlarmDelay=10 C_OilTempHighAlarm C_OilPresLowAlarm=35 C_MaxPLubOil=100 C_MaxTOilinlet=600 C_RPMMCR-940 CNCylet1 C_RpmRun=80 C_MinRpmalarm=100 C_MaxRpmDeviationAlarm=100 C_IndextowAlarm C_PumpintervalTime=43200 C_PumpStopTime=60 C_TrigPosch4{0} (C_TrigPoschi[1}=102 ‘ C_TrigPosCh1(2}: (CTrigPoschi[3} CTrigPosCh1(4]=381 C_TrigPosch1{5]=502 C_TrigPosCh1{6]=542 CTrigPosChi{7]=657 CTrighosch1[8]=766 C_TrigPosCh1[9]=847 _TrigPosCh1(10]=929 C_Trighoschi(11]=0 Page 2APL ROTTERDAM NEW SW VERS. C_TrigPosch1(12)=0 C TrighosCh1(13}: 024 CTrigrosch2{ai Crigroscha{5]=0 C.TrigPosch2{6)}=0 CTrigPosch2[11}=0 C Trigrosch2[12}=0 CTrigPosch2[13]-0 TotalTrigch2=0 C_TrigSystemMode=angleencoder C_Minj=469 C_ModbusUnitN ‘C_ModbusBaudRate=9600 C_ModbusStopsi C_ModbusParity-none _Modbusbatabi C_ModbusProtocol=ansii ‘C_Modbusinterface=rs232c ‘C_ModbusHandshake=none _InjectionAngle(0]=0 C_InjectionAngle(1] C InjectionAngle(2] C_InjectionAnglef3} C_InjectionAngle(4) C_InjectionAngle5]=( C_InjectionAnglefé C_AnjectionAngle(7]=0 CInjectionAngle[8}-0 C_InjectionAngle{9}-0 C_InjectionAnglef10]=0 C InjectionAngle{11]=0 C_InjectionAngle[12]-0 C_InjectionAngle[13]=0 C_TDCMarkert0ffset=0 C_TDCMarker2Ofiset=0 C_TDCMarker30ffset-0 C_TOCTriggert0ffset=0 C_TDCTrigger20Ffset=0 C_PumpMode=automatic C_DefaultPump=p1 C_UntimedMinFeedRate=150 ‘CLubsetupVersion=$ProjectRevision: 1.38 $ C_FeedRateSettingMin=40 C FeedRateSettingMax=200 CCaleulatedBasicOffset=279 C_MaxlimitMecDelay=450 CLcDFactor=125 C_FeedRateSettingMaxNormalService=120 Page 3 1.77 091010.tetAPL ROTTERDAM NEW SW VERS. 1.77 091010.txt C_NormalMax=150 ¢_MSeuffing=200 C_AbsoluteMin=31 C_MEPRelativetimit=63 C_POWERRelativeLimit=40 TotallubinjVolume=0 C_Telegraphsignalscal 00 Page 4EXHAUST GAS TURBO-CHARGER 4 & &Turbocharger BAe Operation Manual RikAS TPL85 - B14/15/16 IH #RRH1H1 Type TPLES-815, Xi 2080911923, mae 550 a 3 r 487. tema 520 _ c 38 1HI Corporation IHI NV11RB-3.R1\We reserve all rghts inthis document and in the information con- tained herein, Reproduction, use or disclosure to third parties without express authority by Hl Corporation i strictly forbidden. © Copyright by 1H Corporation Design and spacificatons are subject to change without notice. Ai EREALOCRBICe rT SIMO. aL mR Er, BRINE RRO AMET SCEECREBIZCY aa © Copyright by IH! Corporation BONE WTS ATER ET OLE AMET OCS TREO,nviicos, Operation Manual List of contents BR Page 1 List of contents AK 4 Preliminary remarks 1 Pa 414 Purpose of the manual La w=27 OB / AR 4.2 Layout and function 12 ites 1.3 Correct use of the turbocharger 13, WRROELWRAAE 4.4 Essential information 14 RHR 15 Abbreviations and symbols LS Beli 7 4.6 Turbocharger rating plate 1.6 ARERR 2 Safety 2 Re 2.1 Basie safety instructions 21 RSICMTSERHOHER 2.2 General safety instructions 22 RECEP SRR 23 Special safety instructions 23 SCAT ORR 24 Safety instructions and hazard 24 RRHRERIE protection 2.5 Warnings on the turbocharger 25 © Sersea 3 ‘Commissioning 3 20) 34 Oil supply 31 fea 3.2 Inspection work 3.2 RARYESE 3.3 Putting into operation after laying up 3.3 PRILGLOD ALY 4 Operation 4 Bc 44 Servicing work 41 Bok 4.2 Monitoring 42 HR 43 ‘Surging of turbocharger 43 MRROY-—W7 44 Contact with rotating parts 44 Bl OEE RA 45 ‘Shutting the engine down 45 YY OPE 5 Maintenance 5 RVFTYA 5.1 Foreword to Maintenance 51 AVF TVA eT 5.2 Cleaning the filter silencer 5.2 WERORe 5.3 Cleaning the compressor during 5.3. ROSY Ly TRIP operation l IH Corporation IHInviicos Operation Manual List of contents 5.4 Cleaning turbine blades and nozzle ring in operation 5.5 Suppliers of materials for dry cleaning Troubleshooting 6.1 Possible remedies for failures 7 Removal and installation 7.4 Turbocharger mass 7.2 Remove the turbocharger 7.3. Installing the turbocharger 8 Disassembly and assembly 81 | Module mass 8.2 Removing and fitting the filter silencer or air suction branch 83 Axial clearance 8.4 Dismantling the internal part of the compressor casing 8&5 Dismantling gas inlet casing 8.6 Fitting gas inlet casing 87 Fitting the internal part of the compressor casing 88 Table of tightening torques 9 Taking out of operation temporarily 9.1 Possibilities for emergency repair 9.2 Locking the rotor 9.3 Blocking the inlets and outlets 9.4 Bypass the turbocharger 10 Mothballing the turbocharger 10.1 Taking out of operation for up to 12 months 10.2 Taking out of operation for more than 12 months BK 54 55 88 oa 9.2 93 94 10 10.1 10.2 Page 2 Bie ogee FUE JAIN SY DGS KAS 7 BORE NIT Ye FAT BREAORUE ORL E ROR E RBOBAL BRO BYRRERESE aeRO BABEL RERRAMOBAL BLUR TRUANIIT IVA BYP LY FA OBA HAMAZ YY OBL LY OST BTN — ER SEER Rd ATHE BJO AABLUBABAD OSE BRR 18% SPRL OS SRIEMAMIAS 12 7A COME PRILMMDS 12 7 EARS THI Corporation THINvitcos Ll Operation Manual List of contents 11 Reserve and spare parts 14.1 Ordering spare parts 11.2 Directory of part numbers 11.3 General view of turbocharger 11.4 General view of cartridge group 12 Guide to service stations THI Corporation BK ll ua uz 3 ud w ae FROME Bese WhO Hel eve—-2 Ny YORER PoeRAT yay Page 3 THIPreliminary remarks Pe eRNvi1013.R1 Operation Manual Preliminary remarks Fine 7 Purpose of the manual 1 Preliminary remarks 1.1 Purpose of the manual (Operation manual This operation manual will help you to become familiar with your turbocharger and to use it to full effect in its intended application. You will find important instructions as to the safe, cor- rect, and economical operation of the turbo- charger. Target group The content of this operation manual is in- tended for persons such as engineers, marine mechanics and service technicians who are responsible for the running of the engine and the turbocharger installed thereon. ‘Content of partion manual This operation manual includes helpful infor- mation on the following topics: "Information on the operation of the turbo- charger and ways to prolong the turbo- charger's service life. ® Early awareness and avoidance of haz- ards. ® Minimising repair costs and failure times. This operation manual is a complement to, and an extension of, existing national regula- tions on accident protection and prevention. THI Corporation FEaTOR M/A 14 Page 1 1 PUAN 110 V=aT VO BAS/ FR BR COBBSUABIS, MRE L BMLT RE ENENOT TG —Vav OF CRARELT Wr DOLOTH, ABE BES CELE BROMATERIVERMREATRORDO SERA MEMENTOET, xaos DBRS OASIL, RB UCB ICR ST RBM MO BRICKS OrYY=H7 tieb DAMM A BLO EAR RGERBICLT ver. SaOMOOPE BURA BAIS PF LIOR IOV CRM ORES EATIET, « BM ROMRICHT SRS LOS— CAR SHEET OWE © FAGORMBLLTOMMI (RBI A LUMI LOREM A TE DOE SLFROTEBLOG ECT SEO IU ERA LTOEF. IHI aOperation Manual Preliminary remarks Fie 1 Purpose of the manual waaTVOR/AR 14 Page 2 The instructions included in this operation — ->AHICMMAN TSH TOMRICIMRICAO manual must be followed under all circum- -<&V), stances. A WARNING. In the event of doubt, consult the officer for MDSHA, TIVLOKSHLOEBKDLO safety and accident protection responsible for FRM(EM ICAL TCA, your area, l THI Corporation THIOperation Manual Preliminary remarks Fis ER 1 Layout and function we 42 Page 3 4.2 Layout and function 1.2 RELA 1 | Filter silencer ae Nozzle ring ee DRI : ial plain bearing | Turbine wheel Tee grey 3) | Thnust bearing | Beating casing | AIAN HRT | [Real pain bearing yo Difuser FET A F47a-F F a 41 _ | Compressor wheel | ayTeyy 9 |Gasinletcasing | 42 |Airoutiet casing | HART aaeyhing7 | THI Corporation THINvHOLaRt Operation Manual Preliminary remarks FR 1 Layout and function ‘ARE mer Page 4 Mode of operation ORB The turbocharger is a turbo-machine and con- sists of the following main components: = Turbine = Compressor ‘These are both mounted on a common shat. The exhaust gases from the diesel engine flow through the gas inlet casing (6) and nozzle ring (7) to the turbine wheel (8). The turbine wheel (8) uses the energy con- tained in the exhaust gas to drive the com- pressor wheel (11), whereby the compressor draws in fresh air, and the compressed air is forced into the cylinders. The exhaust gases escape through the ex- haust pipe which is connected to the gas out- let casing (5). The air which is necessary for the operation of the diesel engine and which is compressed in the turbocharger is drawn through the suction branch of the filter silencer (1) into the com- pressor wheel (11). It then passes through the diffuser (10) and leaves. the turbocharger through the compressor outlet on the air outlet casing (12), The rotor runs in two radial plain beatings (2/4), which are located in the bearing casing (9) between the compressor and the turbine, The axial thrust bearing (3) Is on the com- pressor side. The plain bearings are connected to a central lubricating oil feed which is normally supplied by the oil lubrication circuit of the engine. The oil outlet is always at the lowest point of the bearing casing (8). THI Corporation iAH — RE CHY UF OEM BPs ERNST, = grey 8 BTL IO 2 OMIT MEKRES VET, BLOM AI, AraAOZ— EWA YS (DEHIS EY BIC FEY ORY 7 Vy HERB T SEO CHE RHACTENSAANS—EBALET. CHIE LoTay Ty FEB REI, EES NEBRENVYS ORARDABED, PCV ERB RHA, HAY FNARETTAREEMENES PHRUELT SARA MELT OEY 27 Lo HABE REL EORBRAF 47 2— FUER BYP Ly Oe ee eee DFT byt LSE Y OM Cb SM — VI OIRBEN IE 2 DOFPT VE (2/MIE ORHENEELEF, APAMR@IAYT Ey FOUCDVET. Lavo FE a AT Ai MUMS SEBO GM MC omMo TW F. HERE OMMMN ACRYL 70) OR FRESH NET, THINvTOFaRt Operation Manual Preliminary remarks Layout and funtion The turbocharger is equipped with an emer- gency lubrication oil tank, which is integrated in the bearing casing. With a failure of the lu- brication oil system, the bearings are supplied with oil with this emergency lubrication until the rotor comes to a standstil. L THI Corporation Ft ea 1 SLM 1.2 Page 5 VI ARO RTA ayy SFY IBMT TWET, BMY AT LOE BLEBE, TFET SECON, eT BY APY PS AL BESTE oa IHINvitoraRt Preliminary remarks Operation Manual Fi 1 Correct use of the turbocharger 1.3 Correct use of the turbocharger Latest technology. This turbocharger was built according to state-of-the-art technology and is operation- ally safe according to prevailing safety requ- lations. THI Corporation MRBOELW MEADE 1.3 Page 6 1.3 JERROELV VERA Rok COMMER ORE SMA IC TELE ENTRY BEBO LECT, THINvHOLaRt Operation Manual Preliminary remarks Fie 1 Correct use of the turbocharger Correct use of the turbocharger also includes observation of the assembly, disassembly, ‘operating, maintenance and repair conditions specified 'by the manufacturer. Regulations set out by local authorities must be observed ‘when disposing of the turbine, Petfect condition The turbocharger must only be installed in a technically perfect condition, corresponding to its intended purpose and following the in- structions in the Engine Manufacturers! Manual, and must be operated and used in compliance with the Operation Manual. > Defects which could affect safety must be eliminated immediately. The manufacturer shall not accept liability for damages resulting from unauthorised altera- tions to the turbocharger. 1HI Corporation RROE LEAKE 1.3 Page7 ERIGGMEEL< MTOR, BES: CHARS BIL Ba a Fh ais LUE ORH EF > TCIESUY, ARO BERL Bi, SRERE TOMER OTK Ra, Bare JBL AMO AHORDIC, RERESHOR PRASKCo WEL, MARA GORMAS ETL CRLIRAL KES, D> RSVP SEAS ICAPRL TCE ab, JOAREI UE EY, ERMA CLVECEBRRORETAVMDET. IHIOperation Manual Preliminary remarks FR 7 Essential information BAR 14 Page 8 1.4 Essential information 14 SRR ‘Organizational measures BATT In addition to this manual, the general, statutory regulations applicable in the re- spective country for the prevention of acci- dents and the protection of the environment must be observed. | This also applies to the provision and wearing of personnel protection equipment. z 3 > The turbocharger must be shut down imme- diately in the event of alterations affecting safety or of corresponding operating behav- jour. The fault should be reported to the per- ‘son or department responsible, THI Corporation CORBRA BOMHIC, PAV Le PRARBOR OKSRORS CED MMAEASNET DS, BOTH SRABRORA BLOG AMED BICEDS nwer, > RRCBBPSRAPEL MRE OB (CPEB AIL IBIS AE SETHE, FAOAMES ERIE BA ARELTCREY, THINvIHOL Rt Operation Manual Preliminary remarks Fa 1 Essential information Pa 14 Page 9 Original parts and safety AEMRROSE Original parts and accessories are espe- cially designed for the turbocharger. ‘ABB Turbo Systems and TSU shall not be liable for any damage caused by using non-original parts and accessories. (Qualification of personnel The turbocharger must only be operated and maintained by trained and authorised personnel. PERL ARR, RRO ICBC ANKLOTT, ABB #35E0% TSU HERRERA RCV QOEMALEB ADRS TORIES aunt, (roe MIRON SLO TFL APMRE ENE HDDOIRER ITO CER, It must be ensured that only authorised per- sonnel work on the turbocharger. THI Corporation QP RTE PRE OF DNR BRO TCE THINVIOLARt Operation Manual Preliminary remarks Fa 1 Essential information BAD 14 Page 10 Aftersales service TIE ER For spare parts orders, technical and maintenance work there is a end of this manual (see chap.12) with an updated, worldwide guide to service station of ABB Turbo Systems Ltd. Design variants, This operating manual is valid for various turbocharger design variants. This means that some sections and compo- nent descriptions in this operating manual do not apply to your turbocharger. Our service statiohs and agencies will gladly answer your questions relating specifically to your model. Accuracy of illustrations The graphics and images shown in this manual are of a general. nature and are in- tended to assist understanding of the work steps and instructions. Differences may exist in certain details. THI Corporation FM EOEX, AMS EBL T FLAK OV TSC ORRRASOR 12 HI BABB LOY —-EAAT — Yay OBR MIAME RIEL TSS, TBO ET LOMA B, RAOM MET ELT SRST. LORD, ABOVK VPORPRB BELO HRCA LTE IEBDIET, BELOBRROBISE+ OMMICOWTH, YrEAAT — Yar BLOM EMER ICP bean, AFA EES CORB AOR THRE RAT TOE REBMLETKTSEDOBO CH, MB TT METSAREVET. THINvITOFaRt Operation Manual Preliminary remarks FR, 1 Essential information SRR 14 Page 11 Storage of new turbochargers LU IBRORE New turbochargers supplied by ABB Turbo Systems Ltd or TSU can be stored without additional safeguarding measures for a pe- riod of 6 months after the delivery date. Ensure that the storage area is dry with hu- midity of 40-70% and free of condensation. > After 6 months, rust-proofing oil should be sprayed on exposed surfaces and all accessible areas of the turbocharger. > To do this, the insulating materials must be removed. THI Corporation ABB HHI TSU Ha DeLRAM IBIS, HMDS 6A BLA ECC ET SERCEET. HEE 40~70% CHBOBA LAV RIL KRELTCREUS > 6 FAR, RHBLES OMT WHT (CDRMEATE—LTCRE, dD CORED SLEIL, terval yar ER SLUTS, THINvITORaRt Preliminary remarks Operation Manual Fas, 1 Abbreviations and symbols 1.5 Abbreviations and symbols ‘The following abbreviations are used in this document: D Prerequisite > Work step Result Positive checkpoint (activity that must be carried out without fail) Negative checkpoint (activity that must not be cartied out under any circum- stances) Basic Instructions The following symbol is used for notes in this manual: 16 Page 12 15 BSR 7 KOM AMABICEDNTWET. D ana > RAT YT 2 AR V ENF ey 7 R41 y MME VK RMENIS TrebAVR) X ROF SPRAY ME OLR F COE HEL THU eV) JANES SOR ADRS CIAS POR BRIE FROY DARL eI BE DIVOOET. ABB Turbo Systems The term ABB Turbo Systems used in this manual signifies ABB Turbo Systems Ltd. TSU The term used in this manual TSU signifies Turbo Systems United Co.,Ltd. Official ABB Turbo Systems service station The term used in this manual Official ABB Turbo Systems service station signifies ABB Turbocharger service stations, that have been tested and certified by ABB Turbo Systems Ltd. THI Corporation HRBOHT ABB LIS ABB FRY AF AXILOT ect, TSU REOHET TSU UBF RYAT AAA TAF ON HOreTT, ABB #389 -EAAT—Vay ABCRRANS ABB EBEP—UAAT Ys VEIE, ABB thick CHER “SBME SIT ABB 4 RRM T SREP LAAT Yar tT, IHINvts0r3.Rt Operation Manual a 1 Preliminary remarks “Turbocharger rating plate IBD 1.6 Page 13 4.6 Turbocharger rating plate 1.6 idiiOseik o_|+ THT satin +] 1 ie | xt Fe 2a “4 | t awe 2 ° Pana ete °C 5 7—] t [ | = “gama sane Sear nmpmauapacieee oyacherse + Fr A sapon 8 3 4 ‘Operational irnits Bat 4 Turbocharger operational limits at en- gine overload (110 %). In test rig operation only, unless oth- erwise agreed with the engine manu- facturer. 2 Turbocharger operational limits in ser- vice, Recommended replacement periods / exchange intervals for turbocharger components 3 Replacement interval for the plain bearings in 1000 h 4 — Exchange interval for the compressor in 1000 h (no data for 100,000 h) 5 Exchange interval for the turbine in 1000 h (no data for 100,000 h) THI Corporation PANE (1108) OR MIS SL UAE PCEDSNAVRY, RRLEOREA METH. BOAAAMHORGHAMERBLOY 7a RASA ORR 3 5 SP AEB (x 1000 FFE) SEPT (x 1000 HA) (HERA EY MBEAN 100,000 FF) BEY DBA 1000 FED) (eenSz2V BENE 100,000 FRE) THI ©NVHHOL.RI Operation Manual Preliminary remarks Fat, 1 Turbocharger rating plate BE BORR 16 Page 14 Asional specications: stom 6 Customer part number 6 FkRRES 7 Field for special design designation 8 Mass of the turbocharger in kg 9 Turbocharger type 40 Series number Explanations of the rating plate The recommended exchang: the corresponding operation fir fined together with the engine builder. These specifications are system-specific. L 1HI Corporation 7 LER ORE 8 AHO HAL: ke) 9 eRe 10 Sates ROGAN OB PRAM BLOTS TSAR MARBSAGMOLMESA WET, DSO ASHE, RROMSE DE kote KRRDET. THI>Safety REOperatio Manual Safety gf 2 Basic safety instructions RSCMTSRRHET 21 Page 1 2 Safety 28 2.1 Basic safety instructions 2.1 #2&ICRT SEK The following symbols and terms are used FROST — BLURS, RBPORS for the safety instructions in this manual: HR PVIcebN WET. WARNING nvii023 Ll THI Corporation THINvi1023 Safety Operation Manual ze 2 General safety instructions 2.2 General safety instructions The instructions listed here are designed to ensure your safety and to promote safe handling of the turbocharger and its associ- ated operating materials, CAUTION = Do not work on the turbocharger if you are under physical or mental stress: = Wear protective clothing at all times. - Helmet - Ear protection - . Protective glasses - Protective suit - Oil and petrol resistant gloves ~~ Protective shoes = Attach individual parts and larger com- ponent modules carefully to suitable hoistsilifting devices which are in tech- nically perfect condition and which have adequate load-bearing capacity. = Donot stand under suspended loads. "= Ifwelding work is to be carried out above the turbocharger, the air filter must be covered to prevent damage to the filter mat. = When working on the turbocharger, be aware of the risk of it falling. = For overhead assembly work, use the steps and platforms provided for this purpose. THI Corporation ESCATS MOR 22 Page 2 2.2 RSIS RNR MTSE RITE AE ORLETS ERE, GRE LUGTOBERBEE SI BRI LCRUEET, © DHRKRELRKBOLE OA MIE EBBOTCESH, = WDRSLELRMRERALTED, = Awdyb - Hit + RA atea + fea - Bh / BI OFR + KEK = B+ OMRBLOKE REL ERBIR th, RMS, ERE RRA SH RATAN BR EBSEERLTCRE, = ROSH TOSMRD FIER CE ae, = WHERE E CTIA R74 MEOW BEGCEOIBVEL TES, = CML CR TORICN, BF ORE PARAL TCESU, SRL VALE CORA ERM CIEE ROBAB EMAL TES, THINviw023 Safety Operation Manual RE 2 Special safety instructions 2.3 Special safety instructions Safety when connecting = Work only on those connections for which you are qualified. Safety when commissioning and during opera- tion = Before starting work, make a visual in- spection of the working area. = Remove obstacles and any objects lying around from the work area = Before commissioning check the turbo- charger for damage and leaks. = Refrain from any activity which could compromise safety while working with the turbocharger. = Inspect the turbocharger after about 12 hours of operation or at least once a day for visible damage and defects. = Report any damage or changes in op- erational performance to the per son/department responsible immedi- ately. ® In the event of damage, shut down the turbocharger immediately and secure it advertent or unauthorized use. Safety when cleaning When handling detergents, solvents, acids and alkalis be sure to observe the respec- tive safety directions on the manufacturers’ labels. Follow directions regarding the environ- mentally compatible collection, storage and disposal of these liq THI Corporation RECT OMB 23 Page 3 2.3 REIT SRSA BRERRORS = RRERIRAMAADAMAOTCRAY, HRM BLUE PORE = PREM T OMICS ABC RARLT oRBS RBS MARRS MMICMEL TEED, = RGAE LABS ICHAEL, FMW SAI SRE CDE SH otha, ERE ORS HBA WA, RBLUTAAIAEEATS LEI, ZOMESHOIAMCRAL THERE KBP OE CORREMRICFOTCEEY, Bk, CHOOMAORNK, RERLORRCBL TREE RAD CRO OH RICIES TEE, THI CsNvi1023 Safety Operation Manual ze 2 Special safety instructions A WARNING. = Before cleaning, protect the floor against unintended leaks of oil and operation materials. = You must wear protective clothing (see section General safety instructions). = Handle operation materials and deter- gents with utmost caution, = When handling solvents, wear protective clothing and observe the following rules: - Avoid skin contact with solvents. = Avoid inhaling vapours under all cir- cumstances. - Do not allow solvents to soak pro- tective clothing. = After cleaning, check electric cables for signs of wear or damage. Safety during disassembly, assembly, mainte- nanee and troubleshooting = Follow the prescribed maintenance and inspection schedules for all adjustment, maintenance and inspection work. Inform operating personnel about special work and repairs before starting. * Ensure that absorbent materials are available to clean up any operation ma- terials that escape accidentally. THI Corporation RECT SMB 2.3 Page 4 = RE OR NMSoTH RISC, Hi ATCA Y ORR ERMEL TKS, * QPRERERALTCRES, (OMI SICBIT SAAR) = HRS RHA TRRIRIC+PESL Ka, = BASRMILRRBRER AL ABICE FOR RERERTLTES, - ALATA ESR ELT ww ~ WARSES RG LIRA EHR AI LZ EDEL THEY, - BAAR MICRMSN, RAR EDEL THE, = HRA, BATT VORRERIA BM WF BPTLTCES, RR, MME, AF TV ABLE PREHLAORS PCNRE AVF TY A: BARRA BIC REOMMCRMLTCES, = MER OSRS MT SSSI, Katie BREE CMOE TRAN, = HRASORNADoWRVIIERLH SMUT, IHINv1102-3 Safety Operation Manual RE 2 ‘Special safety instructions = Ensure safe and environmentally-friendly drainage, collection and disposal of op- erating and auxiliary materials. = Before opening a cover or removing a protective component. on the turbo- charger, the engine must have been switched off and must not be started up again until all parts have been properly re-assembled, FSCS SSR 23 Page 5 9 HRM CREASES cao TAL, KERIB OR CMRI BLES, 8 BRBODN— ORBABREBAT ANIC, SYYVENF IESE, FA COM MOST MBM TENSE CRMLAV TEM, ‘Safety when taking out of operation or puiting into storage = Secure the rotor against turning. = Clean . the turbocharger —_before mothballing. = Wear protective clothing when mothballing the turbocharger. = Keep the work area olean.and free of oil and operating materials. = Remove any obstacles lying around on the floor, THI Corporation DCRORAGFLELLREHORS 8 BP ASEMEL TU MEW LEE REBL TERY BGR a hie TTC aa RL CSTE = ARS ROD TONER REAR A AL CES Ww 8 RARE EU MEL, HBLOTEAORNY PRL TR TREY, 8 RICKS RIB EL TAY, THINv11023 Operation Manual Safety ge c Safty instructions and hazard protection 2.4 Safety instructions and hazard protection Associated hazards may arise during opera- tion of and work on the turbocharger: = from the turbocharger and its accessories. = from the operating materials used. = due to failure to comply with the safety instructions. = from inadequate performance of main- tenance and inspection work. Mechanical influences WARNING Personal injury Unconsciousness and injury due to: = crushing = shearing = cutting = winding = smashing = drawing in = knocking = stabbing = rubbing = escape of liquids under high pressure and / or at high temperature = slipping = tripping = falling THI Corporation RARER IE 24 Page 6 24 RSH Re RIE UCR O BUR Bie PERRET. = BRRRLOTONR ADS = BRMRORER AAD = RSHRICEDRAORSA 8 BMRA TTY A: REDD BREA MNO RE ROLINIECEREREY, ABLEVTSE EBEVET, = ORES = HeENS = gbhe = SRAENS = RRae = BeRNS = RODS = wane = RS = MEARLOB CT SR = FRB a ORTS< . &e THInviw023 Operation Manual Safety Re 2 Safety instructions and hazard protection KERR 24 Page 7 Causes me = sharp edges, pointed parts "crush, shear and winding areas = fragmentation / ejection of parts = fracture or rupture of parts due to overload "elastic elements (springs), liquids and / or gases under pressure/in a vacuum = slippery, oily work area, obstacles on the floor Protective measures Y Wear leather protective gloves Y Wear close-fitting protective clothing Y Tie up-long hair and beards (wear hair protection) Y Wear face and eye protection Y Wear protective shoes Y Keep floor, equipment and the turbo- charger clean Y Ensure the availability of oil absorbing materials and have oil collector basins ready or in position Y Eliminate leaks Operation and process materials Operation and process materials refer to chemical and hazardous substances: = Oils = Grease = Coolants ® Detergents and solvents = Acids RUPE MO ROM 8 OBEN, WSENS, SBARNSLIOBPT BB OWE RRR E/ FR DEB dh OA, HIT = BER (Zia), ME FERRE TOMBE Waa 2 HOST, WORN ERE, RICORE D a pao bane Y RMOFREBALTCREY, Dok DLMERRERALTCEEY. ¥ REVERT CRE LER ALTS Ra, Y PCAORBREBALTRAD, Y RBMEAALTCESY, Y RR RA SVIEL TRS Rav, Y WERPPORMSLMEAWTOERE SCL, HE ORM RL TCHS, s Y RARER THEO, PEEL ASR HES LOB MSR MAS, UFO RRLUAEORICSLVET, = ae = FY-R = Bam = Rem SLO A - 1HI Corporation THINvi102-3 Operation Manual Safety a 2 Safety instructions and hazard protection RETIRE 24 Page 8 Personal injury Meno tit The following injuries can be caused by op- -BARISLUE AAEM FOAM eration and process materials: BORBIZSLEDVET, * Allergies = TUR * Skin disease = RB = Loss of consciousness = BRR = Poisoning or nausea after inhalation Causes = Inhalation of toxic gases, smoke and vapours = Skin contact with aggressive fluids = Clothing wet or soaked with hazardous substances = Spilling and tipping over of vessels con- taining substances used duting opera- tion = Escape due to leakage = Tanks and collectors which are not gas-tight and which do not comply with the regulations on hazardous sub- stances = Burning cigarettes or open flame In the proximity of operation materials Protective measures Y - Utmost caution when handling process and operation materials Y Protective clothing must be worn ¥ Avoid skin contact and inhalation under all circumstances ¥ Ensure that the workroom is properly ventilated Y Observe the hazard indications on the containers for operation and process materials Y Immediately after use, seal the hazard- ‘ous substance container tight THI Corporation = RAKLOP REE MMR 8 ABAAE RAERALRES 2 HEREC MS ARISE DR Ay LAST ASA AEA = BI AALS SMSIELEY, UOC DE LRDLEBE = Re MOTH 8 FY7PBBREREN TROT, AH RORO BERRI BA = IGE AMOR CH ASERILAER ORE e Bae Y Bit REEMA SRRILTRAROE BehoCKRS, Y ULPRBREBALTCERV, VY WARSRACOR WARMED Re SAA TED PSE ERIBT TERI, Y PRB ORRELTKES, Y Be RRM AAMAOSBLIRSN TS FERTAARICIRIE TORE, YX SE REDROANOKABREAAT CCL DDBALTCERV, THINvit023 Safety Operation Manual RS 2 Safety instructions and hazard protection Y Used operation materials must be col- lected safely in accordance with the legal provisions, stored separately in suitable containers as prescribed, and disposed of as special waste in a technically and environmentally compatible manner Y Ensure that containers for new / used operation materials are sealed tight Y Inthe event of leaks or spills immediately apply a suitable absorbent material and dispose of this in a technically and en- vironmentally compatible manner as special waste Handling insulating materials Y Ensure that the work area is well ventilated Y Keep the work area clean Y Avoid disturbing dust Y Dust-suppressing tools and processing steps v Remove from packaging only in the work area Y Exercise particular care when removing old insulating materials Y Dispose of insulating materials in a tech- nically and environmentally compatible mannet Y If large quantities of dust are created, wear protective glasses Y Use half or quarter masks Wear suitable work clothing and gloves ‘ Y For sensitive skin, apply moisturising, pro- tective barrier cream. THI Corporation REREAD 24 Page 9| | Y PALUERERAERICEO RS (CE L ROONEMMESBI AR CREL TS FERVY, BLS, MPR BEIEM LL CRIS PLA ET RAMICRED EMBL TCHS Ww VY FLAS LER ROM RMBMOR BL DIMLEELTC REV, Vo BAEK ABS, Boa DAA CHV ILD . DETAR EL CHR PL AVESICRAATIC ALE EMBL TS EW, Avval—yay AR OBR (PSM OBR EL SICAT OTHER, HEROS VERB EAREL TSERU, BBSRAW ECL TES, BEMASLLER- WBS BLTC Ra, BADER OS CHT OTC ESV, SAK < Y BARRO y2l—yayAMERETS PS SHWREBELEO CRAY. VY Avysb—ysy AA RRERRLAVE CRAIC MEO bBLTCSHE, ¥ SRORBRETSBSARB SHRED ALT, Y VAvEEAL, DBLOREB OCHS, MER MBLUEREB ALTERS, Y MAEM ERA, BRESLORER DY DEEL TES, < THINvtt02-3 Operation Manual | | | Safety ge 2 | Safety instructions and hazard protection RSBREERVE 24 Page 10 | . | Noise ar | The effects of noise above a legally permit- ted level can cause personal injury. Personal injury = Loss of hearing = Deafness = Impaired hearing = Health disorders such as loss of balance or of consciousness = Cardiac and circulatory disturbances Causes = Machine noise level above 85 dB (A) Protective measures ¥ Wear ear protection Heat hazard When the turbocharger is operated, surfaces become very hot. Personal iniury = Burns Causes * Missing or incorrectly fitted insulation. Protective measures ¥ Wear leather protective gloves. 1H1 Corporation HUE LEBSNSU NEBR SBI BIE GESTS LLAHVET. Menon = Re = RR = BARS 8 NPY ARES LSA O RS DAN 3 COE RR AES maa «© ROBB 12 85d B (A) EBROBS Daa Y BER EREMALTCRED MILO ER MRROMEY, CORBIEACHMCDVE 0 Anois = AKG saa = 4yvyav TURES Dae viii, ELCRAT SH ¥ RMOFREMALTRED, THINvit023 Safety Wanings on the turbocharger 2.5 Warnings on the turbocharger Warnings that have been applied to turbo- chargers since derivery from works must not be removed, painted over or obscured with other stickers. Missing or illegible warnings must be replaced by new warnings. Operation Manual RE 2 Saka Page 11 25 eR CRATE CRAFT SESIA ER NOMERMVDITENBRE L sv. 86 FREES, E BTFLUBO IAL BRED, TOE d WARNING “CAUTION 24 | ze | ae HAZARDOUS NOISE HOT SURFACE Can cause hearing loss. Gan burn. Put oneas protection. Do not touch surface. Bepares YET. Keowee) at. RERERALTS EEN, RRR T< ESL, d WARNING eS HIGH PRESSURE MACHINERY (Can bum and cause personal injury. |) Do not stay by side of turbocharger. | od | KBSLUGUO ERE VET, i SMO MMICM IRE SATS LEV | IH1 Corporation THI aCommis: ie soning aNvi03-3 Operation Manual ‘Commissioning ao 3 Oil supply 3 Commissioning 3.1 Oil supply A carefully designed oil supply, which func- tions under all operating conditions, is an im= Portant precondition for trouble-free operation of the turbocharger. Lubrication of the turbocharger is_normally caried out with oil from the engine oil circuit. il fitration| ‘A lubrication ol fiter system with a mesh size < 0.050 mm is adequate for TPL ..-B turbo chargers. Oil pressure The oil pressure before the bearings must be maintained precisely to ensure fault-fee op- eration. The permissible oil pressures are specified in the following tables dependent on the lubrica- tion (engine lubrication or separate lubricating system). THI Corporation tL 34 Page 1 3 iH 3.4 eit MARE RMA CHIT SIL STOMA IC BW CBT SLIM EGS AT AER SLEDDVET, GRO TRMOR RY AT Amoe ener, ee SASH TPL BIA aI 0.050mm WFO A FEL TORE, aE AG ORV RSME IEDC MEMOR EMECMRCRET SELECT, PPRMER MRS RMS AT Ase TIT ScASM) (CL TRADES, LF OROLAICIES SHEE, THICommissioning em Operation Manual 3 Oil supply Engine lubrication RB AT ab ‘Separate lubrication system Nvtt09-3 oh Impermissible o-pressure range -> PRAMS > Engine Shut Down (without delay) BIO FT (BERL) 34 Page 2 ‘Short-term (<1h) permissible ol-pressure range > STA LA) CORPSE > ‘Alarm TIA Permissible oi-pressure range for normel operation CORA MER 80-250 Permissible oltpressure range during engine warmup phase RARE O RTE 80-400 impermissible ol- pressure range > HEAOMERR Engine Shut Down (without delay) BBO ry OBER) ‘Shorterm (<1h) permissible ol-pressure range > SPER (1 SMI) CORP ER ‘Alarm TI 90-110 Permissible ol pressure range for normal operation BEBE COSMET 110-260 Permissible oi-pressure range during engine warm-up phase PR PORE 110-400 il temperature during normal operation RICE OE Engine lubtcation BEAT NAO L 1HI Corporation 45 100 160-200 70-90 70 100) 160-200 90-140 THINvi1093 Operation Manual Commissioning ah 3 Inspection work ABER 32 Page 3 3.2 Inspection work 3.2 RIESE This inspection work includes preventive vise ual controls, as well as monitoring and meas- urement to ensure the correct functioning of the turbocharger. These serve as an aid to detecting anomalies before and during com- missioning, thus preventing possible damage to the machine. = The safety instructions must be followed before and during all inspection work. 8.2.1 Inspection before commissioning Monitoring equipment > To be checked for correct functioning. AXctiter mat > Inspect for damage. Lubricating system > Check oil filter for cleanliness before commissioning. > Check oil pressure in oil supply lines. THI Corporation ARI, PHM Cres ARF ar7ICLS FUE RIC LD, BME MICHMELSIRDO CASES LOS OB (CER, 52}, ROMBEHZET. 8 SCO RRR SHRICHES TEV, 3.21 RIOR ext > Bie: panearege DRUM CEEREBL TCE, Baars D> RRBADLCIRIARZ 1 ye DEY LTE, DBP OMES AL CEE. THInvi103.3 Operation Manual Commissioning eh 3 Inspection work URES 3.2 Page 4 3.2.2 Inspection after commissioning 3.22 MBE A Lubricating system WATS > Check oil pressure in oil supply lines. Charger speed > Measuring (Charger pressure > Measuring Temperatures > Measure upstreamidownstream from turbine, compressor and oll feed for various engine speeds Gas, ar, and oll nes > After the engine has been started up, check all gas, air and oil lines for leaks. Further must be observed: > Measure the speed, oil pressure, charging pressure and temperatures before and after the turbine and the compressor at various engine speeds. > Compare the measured values with those of the inspection report, taking into account the different operating conditions. THI Corporation Db ANT OMEARL TREY, sna > Ba b Fey aT vy PHAN BLOTERANO AEE HR BAER CHUL TCE SV, HR, BHR D> KEVE, VA, SRBLUAEMREOSTh DAMP RAL TERY, OKO REI. > iMCMEi- WEARERS: = LP vy F BAD OE EH PIERRE BHBILTTSERU > CHO MEREBERRORY 258 CR ROM FEL TCE, THIOperation Manual ‘Commissioning eh 3 Inspection work 3.2.3 Inspection after 100 service hours Clean or replace lubricating oil filters after the first 100 service hours. Nvi109-3 THI Corporation ROR ERE 32 3.23 100 RRO UR Page 5 (EAN, 100 FEMALES, MMT Fee ISBEIAL TCERV THI aNvit03s Commissioning Operation Manual ao 3 Putting into operation after laying up 3.3 Putting into operation after laying up I provided > Remove the cover plates (blind flanges) between the compressor casing outlet and charge-air receiver, upstream of the gas inlet, downstream of the gas outlet. Inspect the exhaust pipe before and after the turbine for any combustion residue, clean / remove foreign bodies or residual water. Inspect air supply line or fiter silencer for any foreign bodies, clean / remove. Start up the turbocharger’s engine end oil circulation system. Prepare the turbocharger for operation as instructed in the section Inspection before commissioning in the chapter entitled Commissioning. Start up the turbocharger. THI Corporation LEO PSS 3.3 Page 6 33 PRILRORRH PEO S HE b avA byt yO LER EO B EUMAMAD DIRT IVS (BA—7 IY PVEBAL THESIS FCVME ORE CMR EPR, RS PBRMED VEU URL, LRTI CRRR/ BURY TSERYY, BA Ae Se SD EMU aR CR va AL, RB ICIS CC HRNB / BRUTE a, PEPER KES SE MORRE BIBL TES, (ems (AMO AR) OMESRLT SORRELL TEV, Meee TaN, THIOperation ianvi043 Operation Manual Operation ee 4 ‘Servicing work Ba 44 Page 1 4 Operation 4 jie 4.1 Servicing work Servicing work during operation includes vis- ual checks, monitoring and measuring as well as inspection and function checks in order to ensure correct functioning of the turbocharger. It serves as an aid to detecting anomalies during operation, thus preventing damage to the machine. The inspection, measurement and servicing operations listed must be carried out at the intervals indicated. WARNING ‘CAUTION 4.1.4. Servicing work every 25 to 50 hours (Operation data > must be recorded > Enter in the machine logbook > In the event of significant anomalies, es- tablish the cause 41 Bak BEEP ORRFRAERCHM, F277, RHE RARE CR ABF a7 LO FHT EE CH, GRATE BIC PPB COSI EEMEELT foe > MBE RRRICRBAL T bli —sAMSOBET IPAS, BACLT SHANE, TOMAEMBLTIE ah, > THI Corporation IHInvio43 Operation Operation Manual is 4 Servicing work 4.1.2 Entries in the machine logbook Monitoring of the machine plant provides in- formation about the performance of the tur bocharger. The following operation data and measure- ment values must be entered regulariy in the engine manufacturer's machine log book: = Output and speed of the engine "Al intake temperature = Exhaust temperature before and after the turbine = Pressure of the charge-air = Pressure drop in the charge-air cooler = Lubricating oil pressure, lubricating oil temperature ff provided = Air temperature after compressor and after the charge-air cooler = Speed of the turbocharger = Pressure loss in the ait filter 4.1.3. Servicing work according to the engine manufacturer's instructions Ol fiters > With the engine at standstil place oil filters clean or re~ THI Corporation Hh 44 Page 2 412 RE RRORAEH PUERTO LIC LURE ONTO WRERSLLINCEET. UF ORR —F BLOT MSH ORES A SICEMMICELSBAL TEA, = BBO LER 8 BUASERUEE 2 FEV HAR ORAZ = GSE = RMS COE = HUEAEE, MRR BSE 8 SYP BLUER RARE OL ARE = RRO B RK = BRAT FOR DH 413 BEBE TORBCO Baa Be 7 4 D> AEBDASE LL LIRR CAM 17-3 OBE ERERAAIOTC ES, THInvit043 Operation Manual Operation is 4 Servicing work 4.1.4. Inspection work every 18,000 hours > Remove filter silencer or air suction branch > Clean filter silencer as far as accessible, and inspect for damage > Remove the internal part of the compres- sor casing > Check clearance A (axial bearing. clear- ance) > Clean accessible parts (compressor wheel, diffuser, wall insert), and: inspect for damage > Visual inspection of the turbine parts (nozzle ring, turbine diffuserlcover ring, turbine blades) without dismantling, using the endoscope, for possible soiling and damage. As an option, this inspection can also be performed after the disassembly of the gas inlet casing. > Refit the internal part of the compressor casing > Re-install the filter silencer or air suction branch. Bcd 44 Page 3 AAA 18,000 FEED HURTS D WARIS BAL TKS, D> BROTH AAEM TEL ARUBA DRRLTCES, BAYT Ly ATV AMERAL TRE WwW D DIT ILA TRY NAWB IT FLA) BM BUTCH, > DRSNKBR (AYA byt, Fx7a—H, BEB) StL RBM PAUL TCR W Db FEAR VAIS FEY E47 SF ASV, ELT RBA ABT EE, ERG BEV BIC TRIAL TCE RU), EEIELO RURISHAR OS 27 EBA ER FELEDTERT. PBA byt YY 7 AME BUTT TES Ws > WEES ARABERAI TKS, THI Corporation THInvti04-3 Operation Manual Operation at 4 Servicing work 4.1.5 Servicing work every 36,000 hours > Remove filter silencer or air suction branch > Clean filter silencer as far as accessible, and inspect for damage > Remove the intemal part of the compres- sor casing > Check clearance A (axial bearing clear- ance) > Clean accessible parts (diffuser, wall in- sert), and inspect for damage > Remove gas inlet casing, and dismantle nozzle ring > Clean nozzle ring, and check for dam- ageAvear > Clean turbine diffuser/cover ring, and check for damage/wear > Replacement of the radial bearing and axial bearing with new genuine parts > Inspection and assessment of the rotor: THI Corporation Bh 44 Page 4 41.5 36,000 Ree O URS > WER RMAMERAL TCE, D ABOU AAMC E TEL, RA TREBLE TERY, bd ayTrotr We DP DVT ILAR THY AIRE IVT FA) BM BLK. > SSD (F147 2—F, BED) Ei LAR BAIA RRL TREE, Db AARNE VT EBAL, JAI FER PUTER, DP PAV TEBE L, G/DL DFE UTS, BPE F417 2—F ARV ERE, S/R DEBUTS. DFT MMR ET AE LTE RB RICE BLK, b FOR RELO PME RML TREY, VP AME BAL TORS THIOperation Manual Operation i 4 Monitoring en 42 Page 5 4.2. Monitoring 42 Hi 4.2.4 Speed measurement 424 C 3 2 4 | Beating casing | Connecting cable © We iB 2 |AXalbearing 7 |[Lneamplifer (option) Paeaen. 4 PRATT APRA 3 __| Gulden the axial bearing | Speed tansmiter BAR TEL) BEY ITT Installation variant of the 4 | Gasketsing 9 | Seed transmitter ' aye Big he'y 77 97 OBERT i eRe 5 |Sewpug ceca l 1HI Corporation THINvit04-s Operation Operation Manual ite 4 Monitoring The speed transmitter system for the meas- urement of the turbocharger speed also per- mits, in conjunction with the corresponding measuring instruments and/or monitoring systems (not included in the scope of delivery), @ constant remote monitoring of the turbo- charger speed. With continuous monitoring of ‘the machine ‘installation, the turbocharger speed can be used as a sultable control pa- rameter. The line amplifier can be purchased as an optional addition to the described speed measuring system. Possible reasons for failure of the speed indica- tor: = Defects. in the speed transmitter, the connecting cable and plug to the measur- ing unit, in the measuring unit itself or the power supply. = Turbocharger damage. ee 42 Page 6 LOCLIT YT EBD AMEE CE REE (8 DGB TROVE A) BRT SLES TB PERE CHALE AT SCENT 2ky, PHOBREAY AT AR CBRE ERE FBR LL TMOLL CERT. ER FATA OWT) LR OBIE DBM va LLTORRT LEB CERT, NRE ROB: = Bee AOR, oT BRIT, HME HHREECAERORAS = Weiode ‘Arreduction in speed of a charger can signify: * Damaged turbine or bearing = Severe solling of the turbine L THI Corporation gee ace = FEMORIS a F-EYOORW EH THIvito Operation Operation Manual iat 4 Monitoring 42.2. Underpressure measurement on fiter silencer A _Ustube manometer can_be ordered from ABB Turbo Systems Ltd or TSU for measuring the underpressure at the filter silencer. The measurement can be used for the follow- ing purposes: = To measure the correction factor for cak culating the efficiency of the turbocharger when accepting the engine = The use of a filter mat on the filter silencer can cause a loss of pressure. More sig- nificant pressure loss is an indication of increased solling of the filter material. ee 42 Page7 422 WEROETRAE ABOEARAOM EMI, ABB Ht HIE TSU MST IAB ECE SLE CERT, MELA TORMIRA TERT, = @MHEZATSR, DOE RE BRRAEHAT OR = BRMCZ Lewy bees, EAEP eoRoT Lem eye PAMEDBAE SVE BVLEE RIEL TY ar Utube manometer Ie 1 Felt dises | 7 2b yi, ALKPa] Pressure differential / pressure loss — 3S / BEARER THI Corporation THIOperation Manual Operation aie 4 Monitoring All parts required for assembly are supplied in a separate package. Mechanical vibration of the U-tube manometer is reduced by the installation of additional felt discs (1). NOTE > Fit the U-tube manometer to the filter si- lencer as shown in the preceding descrip- tion. > For best readal ter can be filled ter. /, the U-tube manome- th slightly coloured wa- Under as-new conditions (new or clean filter silencer and filter mat), the maximum pressure. loss (A) is 1.2kPa under full loading, > Clean the filter as soon as the loss of pressure (A) reaches a value of 2.0kPa if not before. ee 42 Page 8 RANTES Aa AICS RET AWELET. IAB OBA CIET aI yy HIDE PSLdROMMAN TET, > BEB OT/A-FORHURAONES RLTSREY, > RREMBIOT KT SERbIC, za HC AOHVEAEMRALT ES, FROME MARVIN IE BB LUT 1 MEANT, SRM COED BRANT L2kPa TH. D FEAR (A) #8 2.0kP a BEE TCIER. THI Corporation IHINvi1043 Operation Manual Operation ie 4 ‘Surging of turbocharger 4.3 Surging of turbocharger Surging of the turbocharger can occur with certain engine operating states, such as rapi load removal or while manoeuvring. The di- rection of flow in the compressor is then briefly reversed. However, sporadic surging of this, kind does not generally affect the safe opera- tion of the turbocharger. Action to be taken: The operating safety of the turbocharger is no longer ensured with continuous or periodically recurring surging. The operator must take immediate steps to correct the surging to- gether with the closest official ABB Turbo Systems service station. The components listed above must. be in- spected for damage by an official ABB Turbo Systems service station, and replaced in cases of doubt. THI Corporation Rot 43 Page 9 43 ROY SECAMERS, FEOMEKRICRWTHE WAROI— 777 BECSLEMDVET, TOM, BLT Lot ACMI AELET. Lt LRRD, BRI PV CHUB RROR PHGCVEESAOLOTHOVETA, BONER: RAE ILEMAIEY —PY TPES EB BROMELORSURECEREA, WHAT EEBIO ABB HLIBEDY—EAAT— aC DEBRIRRAERO CHES, MOM AE ROBE ARI, ABB HBEOY— CAA: ACHR, BED tb SATS TERN, THINvii04s Operation Manual Operation it 4 Contact with rotating parts 44 Contact with rotating parts Mild, uniform wear around the circumference of rotor components, caused by slight local grazing against adjacent components, is non-hazardous and permissible. This slightly reduces the length of the blades in the com- pressor and/or the turbine. Certain tolerances, must be observed to avoid significant loss of offciency. > A check on dimensions must be carried out by an official ABB Turbo Systems ser- vice station. THI Corporation RBH 44 Page 10] 4.4 TER OBEAR FORA BD OM — CRU MEFS, BOR RE_THRICITHLOR RACH), CADE DME FAENORR CH, Ty PE RSET BREDA UET, KEE PRALORRLRSOZERT SK, —EOF BWERBL TES, Db PROF ay TIL ABB ALBEDO AAT— ACPA TCIERUY, IHIOperation Manual Operation ae 4 Shutting the engine down DOPE IE, 45 Page 11 45 Shutting the engine down 45 =yVy Otel nvitoes Ll THI Corporation IHIMaintenance RYT TVANvti053 Operation Manual Maintenance RFTYA 5 Foreword to Maintenace 5 Maintenance 5.1 Foreword to Maintenance Cleaning work includes regular visual checks and washing to ensure the correct function- ing of the turbocharger and its auxiliary ap- pliances. = The external condition and the degree of contamination of the cleaning points specified in this chapter must be estab- lished by visual checks at the intervals indicated, ® The safety instructions must be ob- served during all cleaning work. The cleaning points described in the fol- lowing are: Filter silencer = Compressor Turbine and nozzle ring 1HI Corporation RIF TVA AT 54 Page 1 5 AVTTYA 51 AVTTVARbEOT RRA LIME RM bie 5 EIA eR ES Ih, aL 0 HY BOE LE BE HER FEEDOwOTT, IR OMBLLE DVALOI RR hD BNESVSa ARH HEAD CEMMICF zy 7LTCESY, = SCORER CORDIC RICE DUES, BR = Bes a Byte a FEY BERS IHInvtt05-3 Operation Manual Maintenance AYTTYA 5 Cleaning the filter silencer HERO 5.2 Page 2 5.2 Cleaning the filter silencer 5.2 j4#F220¥t% 5.2.1 Filter silencer with tension band 6.21 Fe vse ESR 1.00210 Filter ring (if provided) Cover grids 81265 | Sanne waancneee) | 88 | arya Tension ring Fleece segment 81270 | paw 81188 | see Trap cover ‘Cover panel 81271 eT 81137 HRS Connecting strip Filter silencer body 81268 BOR 81135, WPA E Slide-in module jeece segment + cover panel installed BRIA tRNA ERR THI Corporation THINvii053 L Operation Manual Maintenance RYT FLA 5 Cleaning the filter silencer HEROS 5.2 Page 3 Disassembling and cleaning the filter silencer WERORRBLOTE IF provided Beisi COS EE > Remove filter ring (81265). > Rinse filter ring (81265) with water using detergent or, if very dirty, soak it. Squeeze out carefully: Rinse in cold water. Avoid high mechanical stress (water je). DB PANBY YA C1205) EBL TERY, Db DABVT (81265) OPUNTIA OT ACH REL TCEEVS, FROL OBS IE IDA TASBIRLTCHESU , BERR MAK THM CES. BH, HORE PICT ZAMBIA RB ADD BOE DICTE BUCHE, (A: BAEICLOBEM) > Loosen tension bands (81270) on trap cov- ers (81271) and carefully remove cover grid (81266) from connecting strips (81268). > Pull the slide-in modules (E) out, bend the cover panels (81137) open, and then take out the fleece segments (81136). > Clean fleece segments (81136). When cleaning, ensure that the fleece segments (81136) are cleaned only with mild jet of compressed air, a soft brush or damp cloth. Otherwise the segments may be damaged or lose their shape. THI Corporation b 2FYT(BIAOF YY av SY KB1270) EDT, HM CHR AK (81208) OAS =F Vy KBE BALTES, D> MARTI o— MEE RHL, eRe GUISE ART TC, {LTBI SRL TCE aW, D HBNRLISEEL TAU, GOCROET So LMHSRY DI (81136) ABV ERILER, ROMA IY RE FRM AT CHAI TCV, IHINvit05-3 Operation Manual Maintenance AYFTYA 5 Cleaning the filter silencer Assembling the filter silencer > Assemble the slide-in modules (E) by in- setting fleece segments (81136) in the cover panels (81137). > Bend the cover panels (81137) back to their original shape. > Insert slide-in modules (E) in the grooves in the filter silencer body (81135). > When fitting, insert the cover grid (81266) into the connecting strips (81268). > Fit the tension bands (81270) and tighten ‘on the trap covers (81271). It provided > Fit filter ring (81265). I THI Corporation WERORE 52 Page 4 WHOM D> HDAR(B1136)E HE OAR HRBLIITICALIAA, CHAR ET 2 EERE TCES, DHARMA (81197) BARROW CSTE Yo—/-(B) EEA E135)O Db AA—T7V yk (81266) SHE (81268) TAL b Fy vay srk G12) BHT, 7IL7 (BTDRRBMIT TOES, Big TSS DB FqMAYH 81265 BUTT TERY, THINvi105-3 Operation Manual Maintenance AYFTVA 5 Cleaning the fier silencer WEEORe 52 Pages 5.2.2 Removing / installing the 5.2.2 KBERERIFOBOKL / aati cleaning line L.00192 7 | lesion pipe 2 | Pie BHAT wrA | Guide tube 3 ane l IH Corporation IHIOperation Manual Maintenance BVFTYA 5 Cleaning the filter silencer WERORE 5.2 Page 6 Removing the cleaning line RS RREORAL > Disconnect the line (2) at the injection pipe > zh— AEH S17 (W>ORAL, BED (1) and remove the screw coupling from the RAB Esk ADSHAL TES, pipe: > Withdraw the pipe (2) from the guide tube & 38 A (3) bork AETV TRAV, @). Punchout the guide tube ARO Nvii05-3 00788 > Punch the guide tube (3) out of the caulking & a>Lab CWSifld SANE 16mm) CHRP E with a bolt (diameter = 16 mm) and withdraw ERRE BRO TES, it. NOTE 1H1 Corporation IHIOperation Manual Maintenance RF TYA 6 Cleaning the fier silencer ROR 52 Page 7 Installing the cleaning ine ERI ORNS Loree Nvt105-3 > After fitting the slide-in modules (E), re-fit > MHERHtIke, RAF the guide tube (3) and re-caulk it. GERHHEL, BUSLHT Fitthe pipe (2) and screw to the injection RACER, BU 7) SRLDA, pe : CMELTREY, l THI Corporation THINvit05.3 Operation Manual Maintenance AVTTYR 5 Cleaning the compressor during operation 5.3 Cleaning the compressor during operation The dirt in the compressor stage (compressor wheel and diffuser) depends on the cleanness of the air drawn in and the operating point. ‘A deposit of dirt in the flow ducts will be formed if ‘the following substances are present in the in- take air: = Oilor saline mist ® Solid combustion residues = Dust of various kinds Soiling of the compressor stage has a negative effect on compressor efficiency and charging pressure, particularly for smaller turbochargers. This results in higher exhaust temperatures and increased fuel consumption by the engine. Contamination of the compressor also increases the rotor imbalance. Periodic cleaning of the compressor in operation, prevents or retards a severe increase in soiling, but in no way replaces the regular servicing work, during which the turbocharger is com- pletely dismantied. Interval between cleanings The interval between’ periodic cleaning de- pends in large measure on the operating con- ditions, In general, cleaning should be carried out every 25 to 100 operating hours. THI Corporation RPO T IRE 5.3 Page 8 5.3 Ge Posy Ty tie Sy 7 bo Fl (av 7 VF BLOF 17 2—F) DBR AALR OG E ORE RIBICLY an AEOMRBRAREAPICHSRS, HAT DPIC IERLTOSET: MPM DSS AVTELAP SREB = BX OBR AYA Vy FA DOL VIBE 7 by FBR PUL EZ) ONE PEE, SOREL NTE BRARRVET. LO BRABEREEOL ROMS ER RO WMALKGLET, EK, ayP yt omnia IOV INF AREM KEES, WGP OAS Ly FORMA REE EO FH NR VEO WA BRICK ESD TCRDY ELAR BIRO RSOEHV EVES, DF SDRMDVET, Cy EMME M MEGA RICKa The Operating state preconditions for cleaning compressors with XC3 must be met before cleaning can begin. Remove the screw plug (X). Fill the vessel with pure water. Tighten screw plug (x). Actuate valve lever (Y) against the spring and hold it for 10 to 15 seconds Until all the water has been injected. After cleaning, a waiting time of at least 5 minutes is necessary to allow the turbocharger to dry. vvvy v THI Corporation HEMP ERORR D SIRBAMAIIC, XC3 RSL Ty Pe RP SMM OAT TORT E DERA, FBS I (X)eBAL CRAY, BRICBKEEV TCE, ABT II WEL ODD LAI TOESY SS BNI VA (VRAT IL EBB MEA IA Ket, SHRMEHTSET lO~15 BM RL TERY, PARE 5 AM CM RRS RS ETCEEY, vvvy v THIOperation Manual Maintenance BYTFYA 5 Cleaning the compressor during operation ERPOAT yp RI 5.3 Page 13 Cleaning parameters for each turbocharger. SBOBTER (ALT byt) BO compressor BBENTA-F g TPL 69BA of Possible 1 ie 4 AB: “AY RBPEIBY oman ~ HIS 2 TPL 918 Ll 'H1 Corporation THINvi05.3 Maintenance Operation Manual RTT YA 5 Cleaning the compressor during operation 5.3.2. Wet cleaning compressors with water vessel (XC4) ‘Operating state preconditions for cleaning compressors with XC4 EEO yt 53 Page 14 5.3.2 PeSRIE(XCA) ICES BTV tA XCA CLEA Ly PEO THI Corporation THIOperation Manual Maintenance RTTIA 5 Cleaning the compressor during operation EEPOI Ty 5.3 Page 15 Procedure for compressor wet cleaning with XC LOY Ty FORTE PIE XC4 a 5 00197 4 | Sleaning container 2 [Fire eee TA 3 inlection pipe 1 [Cleaning instructions BSA eR O 5 [cover 3 (valve a7 BUF Ll IHI Corporation THINvI105-3 Operation Manual Maintenance BYFTYR 5 Cleaning the compressor during operation POAT yt 53 Page 16 Use of cleaning container SOS > The Operating state preconditions for cleaning compressors with XC4 must be met before cleaning can begin. > Open filling cap (5) on cleaning container (). Fill with clean water, Screw filling cap (5) back into place. Open valve (6) for about 3 minutes. Close valve (8) and check that all the water has been sucked out. vvyy v After cleaning, a waiting time of at least 5 minutes with the engine running must be allowed so that the turbocharger can dry. > PIP BDMMTIC XC4 ICLBaY TL IIRC TSE GRE OBES TET IEEY Eth, GG BOX yT (5) SANTEE, v PP ABI ATE FREL TREY, Re yT EBACE, SDMA OEM TRYY TORE. AT OVER, ABA TRV SHEA AE BUTEA, RE TARAGKEOLERE 5 DM OURS BEE TKREV, vyvy v Cleaning parameters for each turbocharger compressor SBIR (SLT F) BO. BRAD AF TPL 698A, ee Possible 2 PLT onae bots TPL e0-B FIREPERD naman TPL 85-3 BSNS 3 TPL 91-8 THI Corporation THINvi1053 Maintenance Operation Manual RYTFYA 5 Cleaning turbine blades and nozzle ring in operation 5.4 Cleaning turbine blades and nozzle ring in opera- tion Combustion of heavy fuel oil in diesel en- gines causes soiling of the turbine blades and nozzle rings of the turbochargers. Soiling increases with time, so that regular and properly performed cleaning is important to remove the accumulated deposits. The exhaust gas temperature downstream of the cylinders can rise and the charging pressure at the air receiver can fall if turbine ‘components become soiled. A soiled turbine also results in rotor unbal- ance, Severe soiling can lead to impermissi- bly high rotor imbalance. Experience in operation has shown that de- spite periodic cleaning during operation, it is impossible to dispense with overhauls during which the turbine and nozzle ring are me- chanically cleaned. However, if cleaning is performed correctly and the cleaning system is properly dimensioned, the intervals be- tween overhauls can be extended Wet cleaning interval The Interval between periodic cleaning de- pends in large measure on the operating conditions. In general, cleaning should be carried out every 50 to 500 operating hours. Interval for dry cleaning The interval between periodic cleaning de- pends in large measure on the operating conditions. In general, cleaning should be carried out every 20 to 0 operating hours. L THI Corporation HRROF-EI KE BA PRIN ST OF Page 17 5.4 Wee OY-EYTU—KE PAW YF OB RE FAKE BBR ICIS TE HA BE FSIS KD BOSE Y IL RBLOI AMIS BET, TRL MAL THM TSR EMT DRS ICL CRE TSOEMEBIAVE Te. FEV RRBB NOL RLY —AKOENIET. WF —-EZOWRAABO LRERSILBHY aT. MAT. F-EYOW NRE —POTYANFVA DRROET, BHAGCOLVBA I, B-FO TY AFT ABBE BREBASLEBDVET, EGP OEMMRDE To TORE CH F— EP BEVIAMI YY ERIE T SLSR BIER AE TENT EAE RIB IE BSNTHET, BL, RBESUICR MY ATA BEMCHSILI LIT, FHA ENTS HELLS, tH oO EMO REMMI DEERRICASR ABST SFR SS 50~500 MARAE MAE ICTEIRL TE aM. PADI 27 OF EMORAP MB SBRRRICARE BSH ES, HS 20~50 RMI TMU TIE aW, THI AC Nv T0853 Operation Manual Maintenance Cleaning turbine blades and nozzle ring in operation Cleaning methods Several methods are possible for cleaning the turbine and nozzle ring during operation. The cleaning methods described in the fol- lowing have been tested and are recom- mended by ABB Turbo Systems or TSU: = Wet cleaning * Dry cleaning Principle of wet cleaning During wet cleaning using droplets of water, the water does not act as a solvent, Instead, the deposit is removed by the mechanical impact of the drops. CAUTION Principle of dry cleaning During dry cleaning using dry solid particles in granulate form, the deposit is removed by ‘the mechanical impact of the grains hitting the surface. THI Corporation 5 MPO -EVIL— KE 54 Page 18 PENI I DE BEDE BRP OPEV LIA YI OWIELT, BX DKA Rie CREF, ABBLBLU TSU HIS DUE ORAS MRL, HE KLET: = ARGH BRR HSe KEPORE, PERI CH AIBALL CAE, ie ee KkotTHNERE Let. F349! LY ORE EPA —HVP CHE, BAMF ROD ROBM ARCO THN RMERELET. THINvii053 Operation Manual Maintenance AVETYA 5 Cleaning turbine blades and nozzle ring in operation ‘Stabilsing and drying time Cleaning more than one turbocharger turbine If several turbochargers are installed on one engine, we recommend cleaning the turbo- charger turbines with nozzle rings one after the other. THI Corporation HOST RE 5A PRM AT OF nage RRSOMMRMMAN SES Page 19 1 BOB CBA OMIA TV SBS Ik, JAMES 1 BABI TE SHOLEVELET. THINvtt05-3 l Operation Manual Maintenance AVFTYR 5 Cleaning turbine blades and nozzle ring in operation 5.4.1. Wet cleaning the turbine and nozzle ring during operation at partial power The maximum exhaust gas temperature specified by the engine manufacturer and the Twmax temperature as. shown on the turbocharger rating plate must not be ex- ceeded under any circumstances. During wet cleaning, the turbine is braked and the turbocharger operates at reduced speed. As. a result, less air is supplied to the engine and the temperature after the engine cylin- der and exhaust valve rises. Operating state precondition for wet cleaning 1HI Corporation MPO EVIE PRIVAT DG 5A Page 20 5.41 BaRiBiehOF ee DAYS DYE AEMELSAMARTSHRHAR SRE SLO SAR LICR TIE AE Tae ET I EBIo TITRA, ABERRS EV ICT LS ib) AROMA FLED, LO DF BLOERA EDR O IRIEL, 2 AWTEORERLERLET, AERO RAE THI