TC Operation Manual

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\-' K212ER4 HHI - ABB Turboch arger

\*-,

Operation Manual

YTR 4548/n+2YTR 564F,/N+?,Roll ing contact bearings

Hyundai Heavy Industries Co', Ltd-

ULSAN, REPUBLIC OF KOREA

HHf-ABB Turbocharger

Preliminary remarks

lnstructions onsafety and hazards

Putting into operation

Operation and maintenance

Troubleshooting

,, ,,

Disassembly and assemblY

\-.' Taking out of operation

Appendix

0

2

3.

4

5

6

7

2. Putting into operation

Contents

1Lubricathg oil 2-3 Putting into operation

after out of service period 2-121.1Lubricating oil classifications 2-3 5.1

Putting into operation1.2 after out of service PeriodLubricating oil quantities 2-5 up to 12 months 2-12

1.3 5 .2Filling lubricating oil 2-S Putting into operation

\ after out of service Period\r' 2 of more than 12 moirths 2-12

. Drainhg the gas outlet cashg 2-7

3Cooling water

3 .1Cooling watertemperatures

4

HHI - ABB Turbocl'rarger page 2-1

Page Contents

5

Page

2-7

2-7

Inspection duringputting hto operation

', " 2-9,

4 .1Outline of inspection work 2-g

4.2Inspection before

\-- puiting into oPeration 2-11

4.3lnspection afterputting into operation 2-12

4.4lnspection after100 service hours 2-12

HHI- ABB Turbocharger page 2-3

1. Lubricating oil

Mineral or synthetic based lubricating oils canbe used.Turbine,compressor and hydraulic oils aremost suitable.The engine manaufacturer's recommendationare to be observed.

Engine oils with the usual additives for heavyoil operation are not suitable.

li]nri..,ing oil classifications

Due to the high degree of ageingstability required, onlY - uselubricating oils whose viscosity re-mains within the ranges quotedbelow at 40"C and at 100C (313 Kand 373 Kl.

BcaringtJP

Lubrication systeETurbocbarger

Ty7 VTR

ViskositYtrom1sl [cst]

I4 0 ' c / 3 1 3 K l l 0 0 ' c l 3 7 3 K

I

ViskositY classISO -VG

Vlskosity lnderVI

RolllngcoDtactbearing

- rntegral lubncafionL S l / T S I

- extcndedtg!6icanng oiJ system[ s3 /TS3

tu - 714

a l / 4 < A

<95 7,5 - t2 68 > 8 0

- sdparate c[crnallubricatrng oil sYstemL S 2 i T S 2

l < a l l A < l l 5 7,5 - 16 ,168

100>80

Bearing space cover

16011 / 1801216013 / 48011


Flg.2-l

Ftrg.2-2Oil level plate

0it

HHI - ABB Turboch arge-r" page 2-5

1.2Lubricatirrg oil quantities

ro ril both bearins spaces the rorrowins Fo'lll|: l?fil'fiil:: #l,Jif!i

upper mark

quantities of oil are required:- Place the gaskets (46014/48012) onto the

screw plugs (46013/48011) and tightenthe screw plugs.

Wamingl At commissioning af ter a longin te rva l , the o i l pumP maY note jec t lube o i l .In th is case, f i l l hoPPer o f theo i l pump wi th lube o i l to Pro-v ide connect opera t ion .

1.3Filling lubricating oil

Wamingl Fire risk when handlhg lubricathgoil due to naked flame or smoulder'in9 cigarettes!

Avoid spillhg lubricathg oll

Have a bucket ready for leakhg oil.

Have suhable absobent materialready.

The turtocharger must not be inoperation when oll is belng f illed.

Remove the screw plugs (46013/48011) atthe bearing space covers (see fig. 2- 1).

- Fill fresh lubricating oil through the open-ings into both oil chambers.

VTRComprerror eld

tdrrlTurbbe eud

ladl

l E 4 0 6 0 7 0 3 0 4

2t1 0 t 0 9 oJ ... 0,5

254 1.0 1,3 0 8 l l

3 0 4 L 7 2 0 1 ) r <

3 5.f 1 ,9 , ) 1 3 1 1

451 3 6 4 4 3,0 ... 3,6

564 1 4 8 t 6,8 .. . 7J

1 t l 163 ... 18,0 t4.0 15,6

HHI- ABB Turbocharger page 2-o

51000

Ftg.2-3Gas outlet casing

HHI _ ABB page 2-7

Soak up spilled lubricathg oil whhoil absorbent material

Used absorbent material must becollected separately as specialwaste, and disposed of in the Pre'scrbed used oil contahers.

2. Draining the gas outlet casing

- Open the draining point "0" (see fig. 2-3)ifrd check whether rainwater or condensa'tion hta gathered in the gas outlet casing'

- lf this is the case or is possible, a drainageiine with stop cock must be fitted'

3. Cooling water

The bearing space at the turbine end and theoi'J orift{"cliing (61000) are water-cooledby the engine's cooling system.

In order to avoid conosion use onlysoftened, pure fresh water.

Ventllate the gas outlet casing atthe uppermost poht of the wateroutlet line.

3.1Cooling water ternpratures

The bearing space and the gas outlet casingcan be cooled by a parallel or serial circuit(see fig. 2- 4 and 2-51.

The increase in temperature of the coolingwater serves here a-s an approximate valuefor the volume of water flow.

The increase in the cooling water temperaturemust be set to the following values at full en'gine speed by the installation of orifices in thewater ou t le t oPen ings :

Mhimum water inlet temperature: 30C(303K)

ldeal water outlet temperature: 80C{353K)

Maximum water outlet temPerature- at the bearing casing: <90c((363K)- at the gas outlet casing: < 120C (<393K)

The max. permissible water overpre-ssure is 5 bars.

Legend forfig. 2-4 nd2-5

A) Expansion tank

Tenpcreturelacrease

.tpanlld circult

rc(K)l

atrerld dreuit

l'c(K)l

in the bearingcasilgTE

5 - 1 0 2 - 5

in tbe ges oudetcasiry

8 - 2 0 l t - 2 5

Totel 20-30


Flg.24Cooling rvater parallel circuit

Fig.2-5Cooling water serial circuit

page 2-9

4. Inspection duringputting into operation

Inspection work includes preventive visualcontrols, as well as monitoring and measure-ment to ensure the correct functioning of theturbocharger. These serve as an aid for therecognition of deviations before and duringputting into operation in order to preventdamage to the machine.

- Control and measurement checks must becarried out at the listed inspection pointsat the intervals quoted below.

- Before and during inspection work, the. safety instructions cited in chap' 1 must

be observed. \

4.1Outline of inspection work

Inspection symbols and intervals

lnspection location

Inspection point(visible in the outl ine)

lnspection point(not visible in the outline)

Inspection

Recording of measurement values

Abbreviations for the inspection thnes

Before before putting into operation

After after putting into operation

o\-

\_

ttrV

\

HHI - ABB Turbocl'rarger page 2-10

Fig.2.6

Outline of inspecnion wofk

HHI- ABB Turboch arger page 2-1 1

Item Intenalinspedon 6me

Ilspection polnt Inspection, mcasurqnentand adJustncnt

sGe

obeforeputflng lntoopera6on

Oil space sigbt glasse - Oil levcl Eustcontspoodo up'pcmarting

- bp up if occcssaryscc. 1.3

o Gas outla casing- chcck forcoodcosatioo andrainwatcr

w . 2

o Oil flow monitor - cbcck fuuction Chp.3

@ Vibration mouiton - cbcck fuuctioo Cbry.3

@ Air frltcr scEgrent -cbcct fordamage Chr.3

@ afterputtlng intooperadon

Gas. air andcooling watcr ducts

- cbcck for lcaks scs.4.3

@ Cbager spccd - ltrCasure Chap.3

@ Cbagcr pessure - mcasutl Cbry.3

o Tcopcraores - mcasure bcfore and aftcr urbine andcomprcssor ar various coginc ryccds

Chry.3

4.2Inspection before i, Jputting into operation

- The oil level of the oil spaces on the com-pressor and the turbine ends must corre'spond to the upper marking of the sightglasses.

- The gas outlet casing must be checked forcondensation or rain water (see sec. 2).

- Check that the monitoring devices arefunctioning {see chap.3}. '

Af te r tes t run on the eng ine tes t bed

After the test run drain the oi la t comPressor and tu rb ineend (see chaP.3)and removeboth o i l space covers (see

chap.S). With a c lean brushand a c leaning agent careful lyclean the oi l sumps in both oi lspaces from vis ib le contami-na t ion .

After the c leaning f i t both oi lspace covers (see chap.5) andship the turbocharger withoutoi l to the plant.

HHI - ABB Turbocl-rarger page 2-12

4.3Inspection afterputting into operation

After the engine has been started up,check all gas, air and cooling water l inesfor leaks.

- Measure the speed, charging pressure andtemperatures before and after the turbo-charger and the compressor at various en-gine speeds.

- Compare the measured values with thoseof the inspection report, taking into ac-count the different operation conditions.

4"4.Inspetion after100 service hours

After the first 100 service hours change thelubricating oil in both oil spaces (see chap.3).

5. Putting into operation afterout of service period

5.1Putting into operation afterout of senrice period up to 12 months

In case the turbocharger has beenout of service and been exposedto vibrations for an extended peri-od of time, the rolling contactbearings must be replaced beforeputting into operation.lf a bearing replacement is notnecessary, drah the eventuallyexisting lubricating oil in the bear-ing spaces and fill both bearingspaces with fresh lubricating oil(see chap.3l.

lf applicable, remove the blind flange be-tweon the air outlet casing and the charge-air l ine.

Start up the engine end cooling water cir-culation system.

Ventilate the cooling system.

5.2Putting into operation after out ofservice period of more than 12 months

- Replace rolling contact bearings (see chap.5). ,\-

- Start up the engine and cooling water cir-culation system.

- Ventilate the cooling system.

HHI - ABB Turbocl'rarger page 3- 1

3. Operation and maintenance

Contents

1lnspect'ton

1.10utline of insPection work

1.2Inspection every 25 to 50 hours

1.3lnspection every 100 hours

1.4Entries in the machine logbook

2Monitoring

2.1Speed measurement

2.2Vibration monitoring

2.3U-tube manometer

2 .4Pumping of turbocharger

2.5Oil flow monitoring system E00189/ B

3Cleanhg work

3.1safety instructions

3.2Outline of cleaning work

3.3Cleaning the air fi lter

Contents

3.4Cleaning the cooling water spaces andthe sealing air ducts

3.5Cleaning the cil spaces

3,6Cleaning the turbine

3.7Cleaning the compressor

4Mahtenance-work

4.1Outline of maintenance work

4.2Changing the lubricating oil

4.3Intervals for replacing the bearings -

4.4Intervals for replacing thecompressor wheel

4.5Intervals for replacing the bladed shaft

4,6Intervals for replacing the Pumps

Page

3-3

3-3

3-5

3-5

. 3-5

3-9

3-9

t , " 3-9

3-1 1

3-11

Page

3-21

3-25,

3-25

3-27

3-29

3-29

3-33

3-33

3-34

3-34

3-34

3-1 1

3-14

3-14

3-15

3-19


1. Inspection

Inspection work during operation includes vis-ual checks, as well as monitoring and measur-ing in order to ensure correct functioning ofthe turbocharger, This serves as an aid forthe recognition of deviations during operationin order to prevent damage to the machine.

- Control and measurement checks must becarried out on the listed inspection pointsat the intervals quoted below.

- The safety instructions cited in the corre-sponding chapters must be observed inthe course of all inspection work.

1.1 \

Outline of inspection work

lnspection location

lnspection point(visible in the outline)

Inspection point(not visible in the outline)

lnspection

Recording of measurement values

Abbreviations f or inspection intervals

25-50 thl after every 25-50 serv'tce hours

1OO[h] afterevery 100servbe hours

\"-

\_

DV


Inspection work

2s - so [b]

F ig . r t

Outline of inspecdon work


Ihu hspcOon@tabacc. to srvlcehou:

InrycdonEinEIrpdosrao'

dirmt$l

E/Ery2s to50 thl Opcraicnda

-&

-eolrrintslogbod

- eg+li6 tbccascofdevidicos

s.12

cb4.4

o EEy100 lhl Olps$rgts-.+t€cL oil lcrrd wih ctgiE 4 atudsil

s.13

t

1.2lnspection every25 to 50 hours

- The operat ing data of the exhaust gasturbocharger must be recorded regu-lar ly every 25 to 50 hous and enteredin the maih ine logbook (see. sec. 1 .4) .

- l f the operat ion data deviates signif i -cantly from the data in the inspectionrepor t the causes must bo estab l ishedin accordance with chaP. 4.

- Cal l HHI or ABB i f the reasons for thedeviat ion cannot be establ is,hed.

1.3Inspectionevery 100 hours

- With the engine at standst i l l check theoi l level in the s ight glasses of the oi lspaces a t compressor and tu rb ine end '

- The o i l leve l in the s igh t g lass must bewithin the measurement r ing, i .e. be-tween the max imum and min imummarks (see chap.2) .

- Top up o i l (see chaP.2) .

1.4Entries"in the machine logbook

Monitoi ing of the machine plant providesin fo rmat ion about the per fo rmance o f theturbocharger .The fo l low ing opera t ion da ta and mea-surement va luse must be en tered regu la r 'l y in the mach ine logbook o f the eng inemanuf ac tu rer .

- Output and speed of the diesel engine

- Air intake temperature

- Pressure loss in the air f i l ter

- Pressure of the chargeair

Air temperature after the compressorand the a i r cooler

- Pressure loss of the air cooler

- Cool ing water inlet temperature of theair cooler

( i f appl icable)- Cool ing water inlet temperature of the

gas outlet casing and the bearing cas-ing

- speed of the turbocharger

- Cool ing water out let temperature ofthe gas outlet casing and the bearingcas ing

- Exhaust gas temperature bef ore theturbine

- Exhaust gas temperature after the tur-bine

- Pressure after the trubine or beforethe exhaust gas boi ler

ln the ovent of measurement valueswhich deviate signif icantly from the norm(see the specif icat ions of the engine man'ufacturer and chap.4), establ ish thecause.

Fol lowing a general overhaul of the turbo-charger, the fol lowing data must be re-corded and passed on to HHl .

t ,

HHI- ABB Turbocharger page 3-o

- condi t ion of the drained oi l

- quant i ty and brand of the new oi l

- condi t ion of the air f i l ter

- t ype o f con taminat ion

- condi t ion of the cool ing water spaces

- bear ing change / rep lacement

- o i l pump change

- spare par ts used

- . reorders of spare parts and tools

- service hours

\


Fig. $2Speed maesurement


Fig. $3Vlbraton monitoring

HHf - ABB Turbocharger page 3-9

\ _

2, Monitoring

The f ol lowing monitor ing devices arealready bui l t in or can be suppl ied on re-quest .

2.1Speed measurement

The turbocharger speed is suitable as acheck value for constant monitor ing ofthe machine.

- Electr'rcal measurement system with con-

bearing cover. The frequency is directlyproportional to the speed.

Soeed measurement devices and the corre-sionding accessories are supplied by variousmanufacturers. Further inforinations from theengine manufacturer. ., .,

A r€ductbn ln s@ of a drargr can signify:

damrued turbinedefets in the conncted cylirders (puls€ ogtaiononlv)dock€d grll (pulse operatim only)

the @inrfng of bearing damage

Possble reasons for the breakdown of thespeed indicator:

- Damaged speed measuring device or itswiring

- Advanced compressor end bearing damagewhich,caUSoS the breakdown of the speedmeasurement devices.

In the event of a speed reductbn or break'down of the speed hdicator proceed as fol-lows:

- Reduce the engine speed to idling and shutdown completely

- Check the speed measurement transmitterfor damage or rubbing

- Remove the bearing cover, measure the di'mension "K" (see chap.S) and check thatthe rotor is turning freely.

- lf the value "K" deviates by more than 05mm from the original value (see plate onthe inside of the compressor end bearingcover), the compressor end bearings mustbe replaced.

- Have the replaced bearing checked by anHHI or ABB.

2.2Vibration mmitoring

The vibration monitoring system (see fig.3-3) allows detection of unfavourable opera-tion conditions at an early stage, e.g. rotorout of balance as a result of:- deposits on the turbine blades- damage to the turbine

In the event of an alarm durhg oper-atbo reduce the engine speed in-mediately and check the bearhgspaces md the bearingE

Legend for f ig. 3-3

Electronics rackMainDigitaloutputAlarm / Analogue outputCheck point inputElectronic for single measuring chainConditionerIntegraler transducer (Piezo Electric)

1)2l3)4l5)6)7l8)

HHf-ABB Turbocl'rargel- page 3-1 0

/a'81050

Fig.}.4U - fube rranometer

FlHl- ABB Turbodtarger page 3- 1 1

2.5Oil flow monitoring system ED 0189/ B

Mode of operation

Two similar and mutually independent signal'ing devices (3221 1/34211) monitor the gearoiL pumps (36050/39050) of the turbochargeron the compressor and turbine ends. (see f ig.3 -5) .

Taking into service

Fill both oil spaces with new turbine oil(see chap. 2).

2.3U-tube manometer

The U-tube manometer (s, fig 3-4) measuresthe vacuum in the silencer and thus providesan indication of the degree of contaminationof the fi l ter material.

Vibration of the U-tube manometer (81050)is reduced by the installation of felt discs.

The U-tube manometer must notbe exposed to shock or vibration.

Pumping of turbochargerPumping o f the tu rbocharger can occurin cer ta in eng ine opera t ing s ta tes , suchas rap id load remova l o r wh i lemanoeuver ing , par t i cu la r ly w i th h igh en-gine loading. The general d i rect ion off low in the compressor is then tempo-rar i l y reversed. A l though pumping leadsto increased loading of indiv idual turbo-charger components, sporadic pumpingpu lses do no t genera l l y a f fec t sa fe op-era t ion o f the tu rbocharger . Ex t renne lybr ief impermissible overspeeding canoccur , however , depend ing on the in i t ia lspeed o f the tu rbocharger .

The f o l lowing cornponentscan be damaged by cont inu-ous or per iod ica l l y recur r ingpumping:- compressor whee l (v ib ra t ion

f rac tures , e tc . )- tu rb ine b lades(c racks)- bear ings(overheat ing)- f i l te r s i lencer

Act ion to be taken:The operat ing safety of theturbocharger is no longer en-sured with cont inuous orper iodical ly recurr ing pumping.The operator, together wi ththe engine manuf acturer orHHl , must take immedia teact ion to el iminate the pump-ing .The above components shouldbe examined fo r damage andreplaced in case of doubt.

Observe the instructbns for filllngoil (see chap.Z).

ACaution!

2.4

lf the engine is at a standstill, the lower reddiode on the signaling device (32211/34211) lights up.

\/


36050139050

ABBED 0189/8

OorO rto*

Fig. $5SigDalipg devica for oil flow monitorirg system

f,

The lower, red diodd"Alarm" lightsup (see f ig.3-51 if:

- no oil is flowing- the rotor is at a standstll- the voltage is cut off or- the cables are defctive.

It the alarm indicator lights up dur-ing operation, the enghe must belmmediately slowed down and theoil level checked in order to avoidserious damage to the turbocharg-er.

lf the engine is at a stlllstand andthe power supply cut off, the con-tacts of the output relay are at the"alarm" position.

Despite the fact that the engine isshut down, the turbocharger rotorstill can tum due to ventilation.Thus the oil flows only dody ornot at all out of the transmitter(36050/390501. (Status "Ol(",upper green dbde lights upl bee fig.3-51.

HHI- ABB Turbocharger page 3-1 3


3. Cleaning work

Cleaning work includes regular visual checksand washing to ensure the correct functioningof the turbocharger and its auxiliary applianc-es.

- The external condition and the degree ofcontamination of the cleaning points listedbelow must be established by visualchecks at the intervals quoted.

- During all cleaning work the safety instruc-tions in the respective chapters must beobserved.

3.1Safety instructions

When handling detergents, solvents, acids andalkalis be sure to observe the respective safe-ty directions on the manufacturer's label andin the operation manual. Observe also the in-structions for the environmentally compatiblecollection, storage and disposal of these sub-stances (see chap.1).

Cleanhg work should be carried outoutdoors due to explosion hazards,lf this is not possble, ensure thatthere is adequate ventilatbn.

Before beginning cleaning work hconfined spaces, exthgubh nakedflame {hcludhg cigarettesl} due tothe danger of exdosion.

Always wear protective clothhglsolvent-and ackl resbtant glove+body protectbn and eye protec-tionl. When using chemical cleaningagents the instructions and wam-ings of the manufacture must beobserved.

The same applies analogously todecalcification plants, Gleanhg a'gents and solvents must collected,stored separately h the legally pre-scribed, sealable contahers, and db-posed of in an environmentallycompatble manner.


3.2Outlirre of deaning work

Gleanhg symbols

fi Cleaning location

\ Cleaning point\-{ (visible in the outline)

\_ Cleaning point(hidden in the outline)

Visual check

Washing

Abbreviations for cleanhg intervals

once a week once a week ir serulce

as reqd. as requked

see eng. see enginemanuf. manufacturer


Cleaning work

Flg.}'6Outline of cleaning work

once a week

see eng. manuf.

I.IHI_ ABB Turboch arger page 3-17

Ou'rine of cleaning work

Item Cleaning pointCleaningmeasures

ning intr

tsrequi-rcd

Preliminaries Cleaning agent sae

o - Air filter - washing X

- remove filter

- felt discs

- diesel- turpentine- soap suds

- dry clean

sec.J . J

@

- Cooling watersPaces

- Sealing air ducts

- Gasket grooves

- washing x x - open upperwater outlet

sec.3.4

@- TE and CE

washing oilspaces

. washing x X

- drain oil

- remove bearingsPace cover

- dieselsec.3 .5

@ - Compressor - washing X x- engine at normaloperation

- high compressorspeed

- pure water sec.

o - Turbine

- w€tcleaning

x

- reduced engine load if ma,x.gas temperature beforeturbine is 430 oC (703 K),in no way under 200 oC

(473K)

- pure watersec.J . O

'drycleaning

X- no reduction inspeed

- dry granulatesec.3.6


Fig.},7

Air trlter segments on the silencer

81250

Fig.39

Fitting lilter nats


3.3Cleaning the air filter

Cleaning agents

Cleaning agents for filter mats:- diesel- turpentine- soap suds

Do not bum out the fiher. Burningout destroys the filter.

- Bathe the air f i l ter segment (81ZSO ) in abath of soda solution ( see fig. g- 7 and3-8).

- Allow the segment to drip dry over thebath.

Replachg the f ilter mats

Several air f i l ter segments (81250) enclosethe silencer (see fig. 3-7).

- Fit in f i l ter mats (81257) and cut to thecorrect size (see fig.3- 9).

Cleanhg the sllencer discs

Silencer discs (811501 atd fehedend funnels (811011 maY only bedry-cleaned (see f ig.3-71.

- Remove dirt with rags, a soft brush, orcompressed air-

- Heavily contaminated or loose felt fillingsshould be replaced bY HHL


-31/32/33

Fig.3-10

Overview of the ditlerent channels and the sealing bushes

HHf - ABB Turbocharger page 3-21

3.4ebqr$ng.the cooling water spaces and theseamg alr oucrs

Be careful to observe the safety in'structions when handling cleaningagents (see chap. 11.

Cleaning intervals in accordancewith the information provided bythe plant operator.lf necessary, have the coolingwater spaces cleaned by HHI orABB. \

- lf necessary, detach the turbocharger fromthe engine(see chap.5).

- Dismantle the turbocharger (see chap.5).

- Depending on the type and the, extent ofcalcium deposits, repeat the cle6ning proc-ess until the cooling water spaces in thegas casings are free of calcium.

- Replace all casing gaskets-including thecore hole cover gaskets.

When mounting the core hole cov-ers make sure that the covers arecorrectly positbned on the casing(see chap.7l.

Inspection

- Check manually that the sealing bushes(51014/760021 in the gas inlet casing(51000) and in the air inlet casing (76000)are sitting firmly.

- Replace loose sealing bushes.

- Check that the gasket grooves in the seal-ing bushes are undamaged and free of dirt.


Fig.3-11Overview of the dilferent channels


Check whether the compensation channels(y)-in ttte air inlet casing (76000) as well as(X anO (Z) in the gas inlet casing are clean(see figs. 3- 10).

Assemble the turbocharger aftor cleaning(see chap.5).

Reconnect the turbocharger to the engine(see chap.5).

Fill in lubricating oil in both oil spaces (seechap.2).

Start up the engine cooling water circula't ion system.

Ventilate the cooling system.


CE oll space TE oil space

Fig.3-12Oll spaces

Fig.3-13Oil injection holes in the oil cenfiifuge

HHI - ABB Turboch arger page 3-25

? 6

b'tEuning the oil spaces

The oil spaces on the turbine and compressor;;Jji;;;-i ig, s-12) must be cleaned everviime ttre beaiings are changed.

Before beghnhg work take note ofthe safetf instructions in soc. 3. 1"

- Remove bearing space Gover (46000/48000) (see chaP.5)'

- Drain off the oil (see sec. 4.2)

- Check oil for coarse Particles.

lf coarse metal particles are pres-ent, inform HHI

To prevent corrosbn do not usepetrol.

Clean the oil spaces, gear pump and centri-fuge with rags soaked in diesel.

Do not disassemble the gear PumPunder any circumstances.

- Replace damaged pumps completely.

- After cleaning check that the oil injectionholes in the oil centrifuge leading to thebearing are unobstructed (see fig. 3- 13).

- Mount the bearing cover (46000/48000)(see chap.5)

- Fill with lubricating oil (see chap' 2)'

3.6Cleaning the turbine

General

The burn ing o f res idua l fue ls in d iese leng ines causes fou l ing o f the tu rb ineb lades and nozz le r ings o f HHI -ABB Tur -bochargers and can a lso b lock pro tec-t ion gr ids f i t ted to the engine. This canresu l t in reduced tu rb ine e f f i c iency .lower eng ine per fo rmance, inc reasedexhaust gas tempera tures and in fours t roke eng ines h igher boos t and f i r ingpressures . Opera t ing exper ience hasshown tha t tu rb ine s ide contaminat ioncan be reduced by regu la r c lean ing inserv ice . 1 f car r ied ou t cor rec t ly th isprocedure can lengthen the per iods be-tween overhau l and pro long the t ime aturbocharger can remain in serv icewithout the need for dismant l ing.

In cases where sequent ia l tu rbocharg i -ng is used, part icular ly af ter per iods oflow load opera t ion , care shou ld betaken to regu la r ly c lean bo th tu rbo-chargers"

Two methods o f c lean ing areavai label :wet c leaning {water washing)and dry c leaning (sol id part ic le in jec-t ion) . Which o f the two methods has tobe adopted wi l l depend pr imari ly on theeng ine load and exhaust tempera turebefore the tu rb ine .

Regular cleanhg of the turblne dur-ing operatbn prevents or retardsexcessive formatbn of deposits.

Turbochargers which are contaminated to ahigh degree cannot be cleaned in this wav.

HHI- ABB Turbodrarger page 3-26

In this case the rotor has to be removed (see.chap.S) and cleaned by HHI or ABB.

This cleaning operation does not substitutethe usual maintenance work for which the tur-bocharger must be completely dismantled.

procedure once a week (if necessary).

The two procedure must not be carried outsimultaneously"

Wet cleaning

The tu rbocharger can be c leaned dur in jopera t ion by spray ing in water .Wet c lean ing shou ld be car r ied ou tevery .48-500 hours o f opera t ion . Thein te rva l be tween c lean ing be ing depen-dent upon the ex ten t o f con taminat ionand the inc rease in exhaust gas temper -a tu re a f te r the tu rb ine . The c lean ingshould be repeated when the gas tem-pera ture a f te r the tu rb ine inc reases tozO"C (293K) above the averagetempara ture a t fu l l load .

On ly c lean, f resh water i s rec-ommended fo r wet c lean ingwi th no add i t i ves or so lvents .

Take care to ovserve the in -s t ruc t ions o f the eng ine man-u fac turer fo r wet c lean ing .

The best effect is achieved when cleaningis carr ied out at low engine load (approx.25o/o load).

For the spec i f i c eng ine , the exhaustgas tempera ture be fore tu rb ine mustbe fo l lowed eng ine bu i lder 's recom-mendat ion .

- Cleaning should not begin unti l a constantspeed has been reached.

- Spray in enough water f or 5 or 10 minutesso that it does not all evaporate beforethe turbine.The ideal volume is reached when approx.0,1 l iters/min. can flow through the drain'ing openings "0 ' in the 9as out let casing{see chap.2).

- Eng ines equ ipped w i th more than oneturbocharger connected to the sameai r rec iever may the tu rbochargerssurge dur ing c lean ing . Th is shou ld beavo ided by reduc ing eng ine load.

Dry clean ing

Dry so l id par t i c les a re b lown by com-pressed a i r in to the exhaust l ines be-fo re the tu rbocharger .Th is method o f c lean ing shou ld be car -r ied ou t every 24-48 hours o f fu l l loadopera t ion . The in te rva l be tween c lean-ing be ing dependent upon the ex ten t o fcontaminat ion and the inc rease in ex-haus t gas tempera ture a f te r the tu r -b ine" The c lean ing shou ld be repeatedwhen the gas tempera ture a f te r theturb ine inc reases to 20"C (293K) abovethe average tempare ture a t fu l l load .For a tu rbocharger w i th rnore then onegas in le t , c lean the tu rbochargers onegas in le t a f te r then o ther . On eng ineswi th severa l tu rbochargers c lean oneturbocharger a f te r the o ther .

On account o f the i r hardness , g ranu la t -ed mater ia ls sr . lch as sof t b last media orac t iva ted charcoa l par t i c les have a l lbeen used w i th success .The average gra in s ixe is 1 ,2 -2 ,0mmdiameter

Par t o f the so l ids b las ted incan ernerge smou lder ing f romthe f lue .

Take care to observe the in -s t ruc t ions o f the eng ine man-u fac turer fo r d ry c lean ing .

HHI - ABB Turbocharger page 3-27

- To prevent a h igh ra te o f burn o f f o fd ry c lean ing med ium pr io r to the tu r -bir ie, the gas in let temperature beforethe tu rb ine shou ld no t exceed 580-590r (853-863dK) .

- S ince i t i s no t Poss ib le to removethick deposi ts wi th relat ively smal l a-mounts of soi ld part ic les th is methodhas to be used more f requent ly .

- fn jec t ion o f g ranu la ted drY c lean ingmedium into the turbine is best carr iedout a t a h igh tu rbocharer speed toensure e f fec t i ve mechan ica l c lean ing .

3.7Cleaning the compressor

The following guidelines aPPIY tothe cleaning of the comPressorwith water, insofar as this is Per-mitted by the engine manufacturer.

ln order to achieve optimum cleaning effect, itiJ imbortant that the whole volume of thewatei' is sprayed in within 4- 10 seconds'

- Clean the compressor only with a dosingvessel (27000) (see fig. 3- 14)

l"lnder no circumstances should thespray pipe be connected to a largetink' 6r- a water suPPlY lhe bYmeans of a tap as this could allowuncontrolled volumes of water topenetrate the charger and the en-ghe.

lf no dosing vessel is present, consult theengine manufacturer.

It is essential that the dosing vessel's mounted correctly: at least 1metre below the axis of the turbo-charger.

Thus, in order to Prevent corrosion,only fresh water should be used,and never sea water!

The water should not contain any coolingwater additives which could form deposits inthe compressor.


Fig.3-r4Cleaning the compr.<sor with dming vessel

ooo

, l l

T

HHI _ ABB Turboch arger page 3-29

4. Maintenance work

Maintenance work includes inspection andfunction checks of wearing parts with orwithout chanEing process materials, parts ormodules. lt musf be carried out in accordancewith the intervals as set out in the Outline ofMaintenance work.

Cleaning procedure

1. Release the screw by means of handle (3)from the vessel (1)and lift the cover (2).

2. Fil l the vessel (1) with the volume of wateras set out in the table.

In order to prevent corrosion, onlyfresh water should be use4 andnever sea waterl

3. Replace the cover Ql and tighten thescrew with the handle (3).

4. Press the plunger (4) and.hold it down for10 seconds unti l all of the water has beensprayed. I ,

Function

The plunger (4) opens a valve. This allowscomoressed air from the turbocharger toentei the vessel (1) through the l ine (5), Thecompressed air presses the water through anoperi duct in the cover (2) into the line (6) andfrom there into the compressor.

After cleanhg, the exhaust gastemperatures and the valuse forthe charghg or scavenging pres-sure must return to normal.

In the event of unsuccessful cleaning (valuesnot normalized) repeat at the earliest after 10minutes.lf the values f or the exhaust gas temperatureand the charging or scavenging pressure donot return to normal after the repeated clean-ing process, the reasons must be established(see chap. 4).After the compressor has been cleaned, theengine should be allowed to run for at least 5minutes at full load.

Failuro to carry out the mahte'nance work within the Prescribedhtervals can lead to damage andhoperation of the turbocharger.

The safety hstructions in therespective chapters must be ob'served for allmahtenance work.

Darnaged parts which cottld impaircorrect function must be replaced.

Screw fastenings rnust be tight-ened with a torque wrench (seechap.5l.lf retightening is no longer possble,replace the screw fastenings.

Keep lubrbation and process mate-rials ready.

4.1Outline of maintenan@ work

Mahtenance symbols

Maintenance point(visiblo in the outline)

Maintenance point(not visible in the outline)

Oi lchange

Replace

Abbreviations f or maintenance worksee eng. see enginemanuf. manufacturera/o r. plate and/or rationg Plate16'0oothl after every 16"000 service hours

\_-

\_

tl5

Volume of water required:

VTR tu zr4 E4 304 354 154 56 714

tdEI 0.3 0.3 OJ 0.5 n < t,0 t < 1 <

\-.

HHI- ABB Turbocharger paEe 3-30

Maintenance work

see eng. manuf.a/o r. plate il-s-s-S-El

FE.3-rsOutline of maintcnance work

16'000 [h]

f

\_-


Iten Melnteuenec poht Mdnteuence Eetsurcs

lntcrvrl [bl

l5'000tG3

a Oil pumps - rcplacc x s .4 .5

o Ro[ing coutactb€arings

- replacc conpl. x scc.4.3

o TEaod CEoil spaccs

- chagc thc oil x s.4.2

@ Conpcsscufrccl - nplacc x s.4.4

@ Turbinc. - rcplacc x scc.4.5

Note For the l is t ofp lease re fe r to

spare par tschapt .S :


F8 3,16Bearing space cover

axfl

\ t6010/18010- a6009 / t8009

Fig.3-I7Oil level plate

0iL

4.2Changing the lubr'cating oil

Change hrtervals

The pil must be changed according to the

following table.The increase of the neutralization factor

must not exceed 2 mgKOH/S and the

increase of the viscosity at 40'C(104'F) must

not exceed 2tol.

{

cigarettesl

Have suitalbe contahers readY fordralned oil

Have suitable absorbent materialsready.

Wear oil-resistant gloves.

Avokl spillhg lubricatlng oil' Soakup spillei oilwith absorbent materi-al.

ner.

Before beginningwork take note ofthe safety instructions inchap. 1.

Draining the lubricating oil

- Shut down the turbocharger.

- Place an oil container beneath the screwplugs at the compressor and turbine ends.

- Remove the screw plugs (46009, 46013/+eOOg. 48011) and

'drain off the used oil

(see fig. 3- 16).

- Replace the screw plugs (46009/48009)with the gaskets (46010/48010) and tight'en.


Store used ol h the legalV PI9'Jcrbed containers and dispose of ith an environmentallY compatblemanner.

Fillirrg luhftnting oil

The quantitios of oil necessary. to fill the oilspace's on the cornpressor and turbine endsare set out in chaP. 2.

- Remove the screw plugs (46013/4801 1).

- Fill fresh lubricating oil (see chap. 2) intothe openings in both oil spaces.

- Fill the tubricating oil in accordance to theoil level plate (46015/48013) up to theupper siglit glass mark (see fig. 3- 17).

- Place the gaskets (4601 4/48012) onto thescrew ptugs (46013/480111' insert thescrew plugs and tighten.

4.3hi[eruals for replming the bearings

The rolling contact bearings must be repl-acedii Oamaged, after a standstill period of theiurbochirger in excess of 12 months, or atthe latest after 5 Years.Reblacement inteivals are give by the enginemJnuiicturer and/or the rating plate (s. chap.0).See chap. 5 fo r remov ing and ins ta l la -t ion of the bear ings.

f After the first 100 ssvice hours change, the lubricating oil in

both oil spaces.

zlaWaming! Fire hazard when'hardlhg lubricat'

hg ol from naked flame or lKthted

Mmoi l

temPsaturo

b ( ' F )

C@ling watd

Ntlst tmpsaturc

b ( " F )

Air inlet

t€rnp€raturo

b ( ' F )

lnttrval of oil

changs

Hours

< 1 10(230) <90 ( 194) <lm(104) 10@

< 120(248) < 100(212) <ss( 131 ) 5m

< 130(265) < 1 10(230) 2W

HHf - ABB Turboch arger page 3-34

4.4Intervals for replacing the conpressorwhed

The compressor must be replaced if damagedor at the latest in accordance to the instruc-tions of the engine manufacturer andlor therating plate (see chap. 0).See chap. 5 for removing and installation ofthe compressor.

4.5Inleruds for replacing the bladed sf'aft

The bladed shaft must be replaced if dam-aged or at the latest in accordance to the in-structions of the engine manufacturer and/orthe rating plate (see chap. 0).See chap. 5 for removing and installation of ,the bladed shaft.

4.6Intenrds for replacing the pumps

The oil pumps must be replaced if damagedor at the latest after 16,000 operation hours.See chap. 5 for removing and installatiqn ofthe pumps


4. Troubleshooting

Contents

1Troublescauses, remedies

Page

4-3

HHI - ABB page 4-3

1Thoublescauses, remedies

Trouble Locafion Crutc Rcmedy sec

Erhaust gasteEPerature toohlgb, englrcpcrforueuce andspeed uneltcred

Englne - adts iD injcction En$co - qair or colsttlt cngincnnufadnr

Turbo-chrrger

- lack ofair, c.g. filtcr blockcdby dirt

- comprssor / turbinc conaminatcd

- Exhaust gas b6ct plcssurc too higb

- turbilc bfadr danagedor erodcd

- covcr ring croded

-clco

-clco

-clean cnpahboilcr

- replacc tbc rotor

- r€place

cbtF.3

Chap.3

Cap.5

Ch4.5

Cherge-eircooler

- dirt io the coolcr

- insufEsieot cooling water

- cooling ualcr idet tcGpcraftrctoo higb

- insufficicat veatilation

- clca

- 8oP uP

- cncck / cleao cooliag sYsten

- improvc ncatilation

Ctarge elr pres-ntre too low,eugine perfor-mance and speeduudtered; eirintake normd

Englae - lcat in the air rpceivcr

- lcak in thc gas duct bctwcen cogincadnrbiae

- injcctiou inconcctly adjtstcd

Turbo-charger

- EaaoEetc,r indication dcfcctive

- lrks in thc line to thc mrnometer

- dirt in the air filtcr causiag,cx,cessive p,ressure loss

- dirt iD the comp,ressor / nrbinc

- labrinth t64l dameged

- turbiae / compressor bladcsdanaged

-lroz)e ring danagcd

- cover ring crodcd

- cxhaust gas backprcssrc too higb

- nphcemaoomacr

- rcpair lcak

- clcan

- cleo

- consilt scn'ice station forrqlaccmcnt

- replacc thc rotor

- r4lace

- rcplacc

- claboilcr or rsba[st gassilcocq

Cbap.3

Chrp.3

Cbp. E

rbgf.5

Gap.5

Ch'p.5

t

HHI - ABB Turbocharger page 4-4

Trouble Iocrdon Ceure Ronedy 5eG

Cterge elrpressure too blgb,englaeperformerce endspced uldtered

Englne

Turbo-charger

- manomacr indication incsrrect

- nozzlc ring dirty orpctly obstrTctcd G+.3

Vibredons

Turbecbrrger

- rotorunbalaoce ducto bcarycontaoi!3tio! of cooptssor / t[rbiDc

- tuftiac blads or daupingwircdaoagcd

- bearing dcfcct

-foovlmdclcao,call rcwicc cation

- replace rotor

- rcpbce bcatiag scc& possiblcC'BSC

Cbtp.5

chrF. 5

ehrF.5

Noises on runningqowD,firne too sholtlreluctqnt stard1g

Turbo-cherger

CbT.5

ta"p. t

Ch'p.3

Chap.8

Lcaks in thecasing

Turbo-charger

i

- cncks due to thecroal tensiou

insufEcicnt vcotilatiot

insufEcicnt coolFg wata

dirt in cooling wat€r sp6cc

- nplacc castng

- provi<lc bcttcr ventilafiou

- chcck and to'p up

-clca Cbap.3

Loss oflubrication oll

Turbo-cherger

- scating bushcs (51014 | 76002)danagcd

- conpcDsation dugts X aad Zobstncted

- gaskct ofbcaring spacc covcr lcaking

Chap.3

Cbap.3

cs+.5

Constantpumping of theturbocharger

Turbo-charger

- inocascd flowrcsisaace ducto:

- dirt in thc chargeair coolcror silencer

- hcary dcposits of dirt in thecooprcssor / turbinc

clcan

clca

Gap.3

Chap.3

Engrc - dcfcstive c;heck valvcs intwostrokc cogiacs

- cfihaust 8ss presurc incrcascd aftcrthe turbbc, bccausc thc boilcr ortbs €xhaust gas sileaccr are dirty

- gid dirty

rcplacc valvcs

clcan

clcaa

Cdl the service stetion or representedve ifthe cruse of the pumping cennot bredetected.

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Documents

TC Operation Manual