Accelleron A100-L User manual

Purpose
The ssembly instructions explin how
the turbochrger is fited to the engine
correctly nd without ny helth nd
sfety risks.
Target group
The ssembly instructions re intended
for engineers nd mechnics responsi-
ble for fiting the turbochrger
on the engine.
Assembly Instructions
Turbocharger /
A100-L
Original assembly instructions – English
This document is valid for the A100-L
series:
A165-L, A170-L, A175-L, A180-L,
A185-L, A190-L

Assembly Instructions / A100-L
Table of contents
© Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0002_EN Rev. B May 2022
Assembly Instructions / A100-L
1 Introduction ................................................................................... 2
1.1 Purpose of the assembly instructions .................................................................... 2
1.2 Definition of target group ...................................................................................... 2
1.3 Symbols, definitions .............................................................................................. 2
1.4 Definition of warning, caution, note ....................................................................... 3
1.5 Definition of mandatory signs ................................................................................ 4
2 Safety............................................................................................ 5
2.1 Introduction.......................................................................................................... 5
2.2 Lifting of loads...................................................................................................... 6
2.3 Occupational safety.............................................................................................. 7
3 Weight and transportation of the turbocharger ................................ 9
4 Installing the turbocharger ............................................................ 10
4.1 Placing the turbocharger on the bracket............................................................... 10
4.2 Steps for fastening the turbocharger ..................................................................... 11
5 Storage of new turbochargers and spare parts ............................... 13
6 Further information........................................................................ 17

Assembly Instructions / A100-L
1 Introduction / 1.1 Purpose of the assembly instructions
© Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0002_EN Rev. B May 2022
1 Introduction
1.1 Purpose of the assembly instructions
The assembly instructions explain how the Accelleron turbocharger is fitted to the engine correctly
and without any health and safety risks. This element of the documentation is supplied with the
product, as is required for partly completed machinery in accordance with Machinery Directive
2006/42/EC.
The assembly instructions are a complement to and expansion of existing national regulations for oc-
cupational safety, accident prevention and environmental protection.
1.2 Definition of target group
The assembly instructions are intended for engineers and mechanics responsible for fitting the tur-
bocharger on the engine. Basic mechanical training is a prerequisite.
All persons who are involved in the transportation and installation of the turbocharger have read and
understood the assembly instructions.
1.3 Symbols, definitions
Symbols
The following symbols are used in this document:
uIndicates an action step.
1. Indicates a numbered action step.
¡Indicates a list.
[→ ] Refers to a page number
The trademarks of outside companies are used in this document. These are marked with the ® sym-
bol.
Design variants
This document is valid for different design variants of turbochargers. There may be sections and de-
scriptions of components that are not relevant for a specific turbocharger variant.
Accelleron service stations will be happy to provide information about questions regarding a design
variant (see "Contact Information" on the website www.accelleron-industries.com).
Accuracy of illustrations
The illustrations in this document are general in nature and intended for ease of understanding. Dif-
ferences in detail are therefore possible.
Page 2 / 17

Assembly Instructions / A100-L
1 Introduction / 1.4 Definition of warning, caution, note
© Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0002_EN Rev. B May 2022
Accelleron
Accelleron Industries Ltd is referred to in this document as Accelleron.
Official Accelleron service stations
Accelleron service stations are regularly audited and certified by Accelleron Industries Ltd (see "Con-
tact Information" on the website www.accelleron-industries.com).
1.4 Definition of warning, caution, note
WARNING
Definition of Warning
Non-compliance or inaccurate compliance with working or operating instructions in-
dicated by this symbol and the word WARNING can lead to serious injuries to per-
sonnel and even to fatal accidents.
uWarning signs must always be observed.
CAUTION
Definition of Caution
Non-compliance or inaccurate compliance with working or operating instructions in-
dicated by this symbol and the word CAUTION can lead to serious damage to en-
gine or property with grave consequences.
uCaution signs must always be observed.
NOTICE
Note
The note provides advice which facilitates the work.
Page 3 / 17

Assembly Instructions / A100-L
1 Introduction / 1.5 Definition of mandatory signs
© Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0002_EN Rev. B May 2022
1.5 Definition of mandatory signs
To be worn at all times
Protective clothing Safety footwear to protect against
mechanical hazard and risk of fall-
ing
Table1: Personal protective equipment to be worn at all times
To be worn specific to the respective task
Safety glasses Safety goggles
Safety gloves to protect
against
- Mechanical hazard
- Chemical hazard
- Thermal hazard
Respiratory mask to protect
against
- Dusts
- Gases
Safety helmet Ear protection
Table2: Personal protective equipment to be worn specific to the respective task
Definition of pictograms
The following pictograms can occur in this document. These point out actions that must be taken in
accordance with the meaning of the relevant pictogram.
Pictogram Meaning Pictogram Meaning
Tighten with specified torque Affix
Tighten over specified tighten-
ing angle
Measure
Hand-tight, tighten without tools Note
Oil Visually inspect
Apply screw locking paste (e.g.
Loctite)
Please note text for numbered
work step.
Apply high-temperature grease See document
Apply other paste in accordance
with specifications
Dispose of in an environmentally
compatible, professional way and
in compliance with locally applic-
able regulations.
Oil free, grease free and dry
Table3: Definition of pictograms
Page 4 / 17

Assembly Instructions / A100-L
2 Safety / 2.1 Introduction
© Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0002_EN Rev. B May 2022
2 Safety
2.1 Introduction
State of the art
Turbochargers manufactured by Accelleron are state of the art and comply with the respective
health and safety standards in effect at the time the turbocharger was built. This ensures safe opera-
tion of the turbocharger.
CE conformity information
Accelleron turbochargers comply with Machinery Directive 2006/42/EC and are partly completed ma-
chinery as defined by Article2g.
Residual risks
Nevertheless, there may be some residual risks during operation of and work on the turbocharger
which:
¡are caused by the turbocharger itself or its accessories.
¡are caused by the operating equipment used or supplies and materials.
¡are a consequence of insufficient compliance with safety instructions.
All of the instructions contained within this chapter must be followed when working on the turbochar-
ger.
Responsibility of the operating company
In awareness of its responsibility, the operating company must ensure that only authorised personnel
work on the turbocharger, who:
¡Correspond to the target group (see Definition of target group →2).
¡Are versed in the general and locally applicable regulations for occupational safety and accident
prevention
¡Are equipped with the prescribed personal protective equipment
¡Have been instructed in the use of the turbocharger.
The safety-conscious work of the personnel and adherence to the assembly instructions must be
checked periodically.
Suitable working materials and personal protective equipment must be kept in a perfect condition.
Page 5 / 17

Assembly Instructions / A100-L
2 Safety / 2.2 Lifting of loads
© Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0002_EN Rev. B May 2022
2.2 Lifting of loads
WARNING
Suspended loads
Loads that are not attached according to regulations can cause injury to personnel
or fatal accidents.
uLoads must always be fastened to properly functional lifting gear with a suffi-
cient load limit.
uPay attention to the correct attachment of loads on the crane hook.
uPeople must not stand beneath suspended loads.
Wear safety gloves to protect against mechanical hazards.
Wear safety helmet.
Fig.1: Attachment of loads on the crane hook
Fig.2: Attachment angle
If there are two or more suspension points, the attachment angle of 45° must not be exceeded. This
prevents excessive loading due to diagonal pull.
uUse a suitable edge guard if there are sharp edges.
uThe assembly devices must be completely screwed in and must not unscrew during use.
uUse assembly devices only for the described applications.
Page 6 / 17

Assembly Instructions / A100-L
2 Safety / 2.3 Occupational safety
© Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0002_EN Rev. B May 2022
2.3 Occupational safety
General
WARNING
Injuries to persons
Severe injuries to personnel or fatal accidents can be caused by mechanical influ-
ences as a consequence of hazardous and inadequate operational procedures or
non-compliance with safety and health standards.
uWhen working on the turbocharger always wear safety footwear and protective
clothing to protect against mechanical hazards.
uKeep personal protective equipment in perfect condition.
uObey mandatory signs.
uObserve the general rules for occupational safety and prevention of accidents.
uOnly perform operations that are described in this document.
uOnly perform operations for which you have received instruction or training.
Wear safety footwear to protect against mechanical hazard and risk of falling.
Wear protective clothing.
WARNING
Risk of falling
When working on the turbocharger, there is a risk of falling.
uDo not climb onto the turbocharger or onto attached parts and do not use them
as climbing aids.
uUse suitable climbing aids and working platforms for work above body height.
uOnly perform work on the turbocharger when you are in a physically and psychologically stable
condition.
uOnly work with suitable tools, equipment and appliances that function properly.
uKeep the workplace clean; clear away any loose objects and obstacles on the floor.
uKeep the floor, equipment, and turbocharger clean.
uHave oil binding agents ready and provide or keep oil pans at hand.
Welding work in the vicinity of the turbocharger
uWhen performing welding work in the vicinity of the turbocharger, always cover the filter silencer
to prevent the filter mat from being damaged.
uKeep flammable objects and substances out of the vicinity of flying sparks.
uCover all connections on the turbocharger so that no foreign objects can enter the turbocharger.
uWear personal protective equipment (PPE) for welding operations.
Page 7 / 17

Assembly Instructions / A100-L
2 Safety / 2.3 Occupational safety
© Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0002_EN Rev. B May 2022
Mechanical hazards when working on the turbocharger
WARNING
Physical hazards due to rotating parts
The rotor can rotate due to the stack draught alone. Contact with rotating parts
can cause severe injury.
uSecure rotor against turning.
WARNING
Mechanical hazard
Severe injuries to personnel or fatal accidents can be caused by mechanical influ-
ences as a consequence of hazardous and inadequate operational procedures.
uObserve the general rules for occupational safety and prevention of accidents.
uEnsure workplace safety.
uOnly perform operations that are described in this chapter.
uOnly perform operations for which you have previously received instruction or
training.
Hazards due to operating materials and supplies
Operating materials and supplies can include: Oils, greases, coolants, cleaning agents and solvents,
acids or similar substances.
WARNING
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or contact with
them may be harmful to health. Flammable and combustible operating materials
and supplies can catch fire or resulting vapours can lead to an explosion.
uDo not breathe in these substances and avoid contact with the skin.
uEnsure proper ventilation.
uObserve the information in the material safety data sheet for the operating ma-
terials and supplies.
uComply with local legislation.
Wear safety goggles.
Wear safety gloves to protect against mechanical hazards.
Wear a respiratory mask to protect against gases.
Page 8 / 17

Assembly Instructions / A100-L
3 Weight and transportation of the turbocharger / 
© Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0002_EN Rev. B May 2022
3 Weight and transportation of the
turbocharger
Lifting gear with a sufficient load limit must be used for removing, installing and transporting the tur-
bocharger. The weight specified below applies to the heaviest variant possible. Depending on the
specification, the weight specified on the rating plate may be lower than the standard value specified
here.
Fig.3: Fastening of the turbocharger
Product Weight of complete turbocharger unit [kg]
A165-L 2300
A170-L 3300
A175-L 5600
A180-L 7500
A185-L 10500
A190-L 13500
Table4: Total weight
Page 9 / 17

Assembly Instructions / A100-L
4 Installing the turbocharger / 4.1 Placing the turbocharger on the bracket
© Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0002_EN Rev. B May 2022
4 Installing the turbocharger
4.1 Placing the turbocharger on the bracket
Fig.4: Placing the turbocharger
uRemove covers from the oil connections.
uAlign turbocharger and place on engine bracket.
uTighten the fixing screws (Steps for fastening the turbocharger) while only slightly loosening the
lifting gear.
uRemove lifting gear from turbocharger.
uConnect cable to speed sensor.
uConnect all gas, air and oil pipes.
Page 10 / 17

Assembly Instructions / A100-L
4 Installing the turbocharger / 4.2 Steps for fastening the turbocharger
© Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0002_EN Rev. B May 2022
4.2 Steps for fastening the turbocharger
General information
Subject Requirement / Information
Turbocharger fixing elements ISO property class ≥ 8.8
Washers Hardened, thickness ≥15% nominal thread diameter
Dimension a (compressor end) a = height of turbocharger foot a
Dimension a (turbine end) a = height of turbocharger foot F + spacer sleeve D
Dimension b Hole in bracket
Dimension c Thread length, ≥ 1.5 x nominal thread diameter
Coefficient of friction 0.12 (lightly oiled)
Table5: General information about fastening the turbocharger
Compressor-end foot
Fig.5: Compressor-end foot
uTighten the foot fixing screws or nuts diagonally according to the selected tightening method.
Turbine-end foot
Fig.6: Turbine-end foot
uTighten the foot fixing screws or nuts according to the selected tightening method.
Page 11 / 17

Assembly Instructions / A100-L
4 Installing the turbocharger / 4.2 Steps for fastening the turbocharger
© Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0002_EN Rev. B May 2022
Torque-controlled tightening
Product Thread size Height a of foot
[mm]
Tightening torque
[Nm]
A165-L M22 86 440
A170-L M27 100 830
A175-L M30 120 1100
A180-L M33 136 1500
A185-L M39 151 2500
A190-L M42 167 3100
Table6: Tightening torques (foot screws)
Angle-controlled tightening
Product Thread size Height a
foot
[mm]
Pre-tightening
torque
[Nm]
Tightening angle
height a
[DEG]
Additional
tightening angle for
every 10 mm of addi-
tional screw length b
[DEG]
A165-L M22 86 120 30 3.7
A170-L M27 100 220 30 3.1
A175-L M30 120 300 30 2.6
A180-L M33 136 400 35 2.6
A185-L M39 151 600 35 2.4
A190-L M42 167 700 35 2.2
Table7: Tightening angle (foot screws)
Pinning of turbocharger feet with positioning pins
If the turbocharger is pinned at its feet, one pin hole per foot must be used.
Page 12 / 17

Assembly Instructions / A100-L
5 Storage of new turbochargers and spare parts / 
© Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0002_EN Rev. B May 2022
5 Storage of new turbochargers and
spare parts
Storage of new turbochargers and spare parts for up to 6 months
New turbochargers and spare parts can be stored in their closed packages for 6months from the
date of delivery without additional mothballing measures.
Only dry rooms in which the relative humidity is between 40…70% and no condensation can form are
suitable for storage.
Storage of new turbochargers and spare parts for more than 6 months
As the contents of the package are adapted as required, turbochargers may also be delivered
without a VCI label.
For parts with a VCI label on the package, the following instructions must be observed.
Fig.7: Volatile Corrosion Inhibitor (VCI)
WARNING
Health protection when handling VCI
VCI products are not hazardous in terms of the Ordinance on Hazardous Sub-
stances. Nevertheless, the following points must be observed when handling VCI:
uObserve information in material safety data sheet
uEnsure proper space ventilation.
uDo not eat, drink or store food at the workplace while working with VCI.
uClean hands and face after working with VCI.
uFor more information, see www.branopac.com.
Wear safety gloves to protect against mechanical hazards.
Every 6months, the following mothballing measures are required:
uOpen package.
uRemove VCI corrosion protection emitter from package and replace with a new VCI corrosion pro-
tection emitter of the same kind. New VCI corrosion protection emitters can be obtained from
www.branopac.com.
uOld VCI corrosion protection emitters must be disposed of in an environmentally compatible, pro-
fessional way and in compliance with locally applicable regulations.
uSeal the package. The more tightly the package is sealed, the longer the protection will last.
Long-term storage of turbochargers
The turbochargers will be prepared for long-term storage if requested in the purchase order. The
package is equipped with a hygrometer (see illustration).
Page 13 / 17

Assembly Instructions / A100-L
5 Storage of new turbochargers and spare parts / 
© Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0002_EN Rev. B May 2022
Fig.8: Package with hygrometer
Every 6months, the following measures are required:
uCheck the hygrometer(02) in the sight-glass. There is an opening(01) in the wooden crate which
allows this check to be carried out. When the display field has changed colour at the 70% level,
the maximum permissible humidity has been exceeded. In this case, the turbocharger must be in-
spected by a Accelleron service station and repacked.
uInspect the package for damage. If the package is damaged, the turbocharger must be inspected
by a Accelleron service station and repacked.
After every 3 years the following work steps must be performed by a Accelleron service station:
¡Inspect the component
¡Replace the desiccant agent
¡Repackage the component.
NOTICE
70% field of the hygrometer has not changed colour
If the 70% field of the hygrometer(02) has not changed colour and the package is
undamaged, the turbocharger can be put into operation without any prior inspec-
tion by a Accelleron service station.
Unpacking the turbochargers
The corrosion protection effect ends after the material is unpacked from the VCI package.
To avoid the formation of condensation, the surroundings and the content of the package must have
the same temperature during unpacking.
Page 14 / 17

Assembly Instructions / A100-L
5 Storage of new turbochargers and spare parts / 
© Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0002_EN Rev. B May 2022
Page 15 / 17

Assembly Instructions / A100-L
5 Storage of new turbochargers and spare parts / 
© Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0002_EN Rev. B May 2022
Page 16 / 17

Assembly Instructions / A100-L
6 Further information / 
© Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0002_EN Rev. B May 2022
6 Further information
The Operation Manual must be observed with regard to commissioning, operation, maintenance and
ordering spare parts.
NOTICE
Operation Manual
The Operation Manual for the turbocharger with the relevant serial number is avail-
able online on our website www.accelleron-industries.com.
Fig.9: Serial number of the turbocharger on the rating plate
One rating plate (01) each is attached on the left and the right side of the turbocharger bearing cas-
ing.
1. Read the serial number(02) on the rating plate(01) of the turbocharger.
2. Find "Operation Manual" section on our website and follow further instructions.
Page 17 / 17

Contact information
Further information
Find your nearest Service Station on the website.
Find and download the Operation Manual of your product on the website
(see “Operation Manuals“).
Accelleron Industries Ltd
Bruggerstrasse 71a
5400 Baden, Switzerland
[phone]
accelleron-industries.com
Visit our website by scanning the QR code.
© Copyright 2022 Accelleron Industries. All rights reserved.
HZTL455311P0002