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ABB HT846171 Operation Manual

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Turbocharging
Operation Manual / A150-M68
HT846171
Document identification
Document number
Revision
Language
Product identification
Serial number
Customer part number
Delivery date (yyyy-mm-dd)
Weight
Operating limits according to rating plate
Speed limit in test rig operation only
Speed limit during operation
Gas inlet temperature limit in test rig operation only
Gas inlet temperature limit during operation
HZTL4041
E
English
Original Operation Manual
HT846171
132884-18050
2021-06-16
1200
n
Mmax
n
Bmax
t
Mmax
t
Bmax
kg
546
1/s
534
1/s
650
°C
620
°C

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  • Page 1 Turbocharging Operation Manual / A150-M68 HT846171 Document identification Document number HZTL4041 Revision Language English Original Operation Manual Product identification Serial number HT846171 Customer part number 132884-18050 Delivery date (yyyy-mm-dd) 2021-06-16 Weight 1200 Operating limits according to rating plate Speed limit in test rig operation only...

  • Page 3: Table Of Contents

    Oil pressure, oil temperature..................43 Exhaust gas temperature before turbine .............. 45 Turbocharger speed ....................46 Operation and service ..................49 Noise emission ......................49 Service work ........................51 © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...
  • Page 4 Installing the cartridge group with compressor and turbine casing ....118 10.19 Installing the gas outlet casing................119 10.20 Installing air inlets ..................... 122 Dismantling and fitting, cartridge concept ........... 123 © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...
  • Page 5 Ordering spare parts....................159 18.2 Required customer spare part set (97070)............159 18.3 Spare part – Illustrations ..................160 Tools ........................174   Figures......................... 176   Tables ........................178 © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 6: Operation Manual / A150-M58/68

    Availability of the Operation Manual The Operation Manual must be available where the turbocharger is used. All persons operating or working on the turbocharger must have read and fully understood the Operation Manual. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 7: Contact Information

    This document is valid for different design variants of turbochargers. There may be sections and descriptions of components that are not relevant for a specific turbocharger variant. Please contact an ABB Turbocharging Service Station if you have any questions regarding a design variant (see Contact information at www.abb.com/turbocharging).

  • Page 8: Layout And Function Of The Turbocharger

    Fig. 2: Layout and function of the turbocharger 01 Filter silencer / air suction branch Gas outlet flange 02 Compressor casing Nozzle ring 03 Diffuser Turbine casing 04 Bearing casing Compressor wheel 05 Turbine © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 9: Fig. 3: Compressor Wheel Cooling

    (X). In addition, the turbocharger version with compressor wheel cooling is indicated by the tur- bocharger type (M6..) on the rating plate. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E...

  • Page 10: Symbols, Definitions

    Caution and warning signs are described in chapter Safety. ABB Turbocharging ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging in this document. Official service stations of ABB Turbocharging Official service stations are regularly audited and certified by ABB Turbocharging. See also chapter Contact information →5.

  • Page 11: Table 1: Definition Of Pictograms

    Visually inspect Please note text for numbered work step. See document Dispose of in an environmentally compatible, professional way and in compliance with locally applicable regulations. Table 1: Definition of pictograms © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 12: Storage Of New Turbochargers And Spare Parts

    Old VCI corrosion protection emitters must be disposed of in an environmentally compat- ible, professional way and in compliance with locally applicable regulations. Close package. The more tightly the package is sealed, the longer the protection dura- tion. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 13: Fig. 5: Package With Hygrometer

    Inspect the package for damage. If the package is damaged, the turbocharger must be in- spected by an ABB Turbocharging Service Station and repacked. After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station: ¡...

  • Page 14: Registered Trademarks

    Operation Manual / A150-M58/68 1 Introduction / 1.7 Registered trademarks Registered trademarks The trademarks of outside companies are used in this document. These are marked with the ® symbol. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 15: Safety

    Safety Introduction Turbochargers manufactured by ABB reflect the state of the art. The respective safety and health protection requirements are met. This ensures safe operation of the turbocharger. Nevertheless, there may be some residual risks during operation of and work on the tur- bocharger which: ¡...

  • Page 16: Definition Of Mandatory Signs

    Non-compliance or inaccurate compliance with working or operating in- structions indicated by this symbol and the word CAUTION can lead to seri- ous damage to engine or property with grave consequences. Caution signs must always be observed. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 17: Intended Use

    These data are given on the rating plate. ABB accepts no liability and rejects all warranty claims for any non-intended uses. [1]Euromot = The European Association of Internal Combustion Engine Manufacturers [2]Directive 94/9/EC concerning equipment and protective systems intended for use in po-...

  • Page 18: Warning Plates On The Turbocharger

    The turbocharger must only be used when it is in a technically flawless condition and oper- ated in compliance with its intended use. ABB excludes any liability for damage resulting from unauthorized modifications to the tur- bocharger or improper operation.

  • Page 19: Turbocharger Rating Plate

    Further data 06 Customer part number 07 Designation for special design 08 Weight of turbocharger in kg 09 Turbocharger type 10 Serial number Year of construction of turbocharger Manufacturing plant © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 20: Fig. 8: Locations Of The Rating Plates

    Operation above the indicated values n can considerably shorten the recommended Bmax Bmax replacement intervals. In such cases, we recommend contacting the nearest ABB Turbochar- ging Service Station. normally apply only when running at overload (110 %) during trials on the engine Mmax Mmax test bed.

  • Page 21: Periodic Check Of The Pressure Vessels

    Operation Manual / A150-M58/68 2 Safety / 2.8 Periodic check of the pressure vessels Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, are so-called "simple pressure vessels". ¡...

  • Page 22: Lifting Of Loads

    The assembly devices must be completely screwed in and must not loosen during use. Use assembly devices only for the described applications. Put down dismantled components of the turbocharger in such a way that they cannot tip over. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 23: Prerequisites For Operation And Maintenance

    Only use original parts from ABB. Original parts and accessories are specially designed for ABB turbochargers. ABB accepts no liability for any damage resulting from the use of non-original parts and cor- responding accessories. © Copyright 2021 ABB. All rights reserved.

  • Page 24: Hazards During Operation And Maintenance

    Do not touch hot surfaces. Observe the warning plate on the turbochar- ger. Wear heat-resistant safety gloves and protective clothing. Wait for the turbocharger to cool down before carrying out any work. Wear safety gloves to protect against thermal hazards. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...
  • Page 25 Operate the turbocharger in compliance with the specifications. Secure the rotor against unintentional rotation during maintenance. Wear safety gloves to protect against mechanical hazards. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 26: Safe Operation

    In case of damage, take the turbocharger out of operation immediately and safeguard against accidental/unauthorised use. When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay at- tention to the risks that may occur as a consequence of this energy input. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 27: Safe Maintenance

    Keep the floor, equipment, and turbocharger clean. Have oil binding agents ready and provide or keep oil pans at hand. Clean up any spills. Have fire protection means and extinguishing agents available. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...
  • Page 28 Components of the turbocharger can be damaged or destroyed as a result of improper procedures. Only perform operations that are described in this chapter. Only perform operations for which you have received instruction or train- ing. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...
  • Page 29 Wear personal protective equipment (PPE) according to the material safety data sheet. Comply with local legislation. Wear safety goggles. Wear safety gloves to protect against chemical hazards. Wear a respiratory mask to protect against gases. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...
  • Page 30 Dispose of insulation materials properly and in an environmentally com- patible manner in compliance with the legal regulations. Wear safety goggles. Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against chemical hazards. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 31: Removing And Installing

    Complete turbocharger unit without gas outlet casing Complete turbocharger unit with gas outlet casing Product Weight of complete turbocharger unit [kg] A150-M58/68 1200 Table 4: Weight of complete turbocharger unit © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 32: Removing The Turbocharger

    If present: Disconnect the plug to the speed sensor (86505) and secure the rolled-up cable on the turbocharger. This protects the plug from being crushed. If present: Detach the support (61301) from the engine support. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E...

  • Page 33: Fig. 14: Loosening The Clamping Nut

    3. Working in a circle, loosen each pressure screw by 90° in 1...5 rounds until all of the pres- sure screws have been relieved. Loosen clamping nut by hand. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 34: Fig. 15: Turbocharger Centre Of Gravity

    Remove and dispose of the O-rings (42195, 42200). Set down and secure the turbocharger properly at a suitable location. Close or cover the openings of the turbocharger and support. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 35: Installing The Turbocharger

    Detail A Screw plug with orifice hole (option) Fit the gasket (42200) on the oil inlet (screw plug 01a or 01b with the orifice hole). Fit the gasket (42195) on the oil drain (02). © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E...

  • Page 36: Fig. 17: Inserting The Threaded Rods

    Placing the turbocharger on the bracket Fig. 18: Placing the turbocharger on the bracket Make sure that covers of the oil and water connections are removed. 1. Carefully lower the turbocharger. 2. Check dimensions again. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 37: Fig. 19: Preparing The Clamping Nut For The Tightening Procedure

    4. Tighten clamping nut (03) by hand. 5. Unscrew clamping nut (03) by ¼ of a turn (90°). The distance between the thrust washer and the clamping nut is now about 1 mm. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E...

  • Page 38: Fig. 20: Tightening Pressure Screws

    4. Work in a circle to tighten all pressure screws to 100 % of the tightening torque specified in the table. 5. Tighten pressure screws to 100 % in 5 … 7 rounds until the required residual tightening angle of < 20° is achieved. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 39: Fig. 21: Connecting The Speed Sensor

    Remove the screw plug on the connection for the compressor wheel cooling (06) and fit the cooling air line. 3.3.6 Attaching the support Fig. 23: Attaching the support If present: Attach support (61301) to engine support or to a connecting piece. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 40: Commissioning

    Filtering the lubricating oil with a filter mesh width of ≤ 0.034 mm is sufficient for this tur- bocharger. 4.1.4 Oil pressure Comply precisely with the oil pressure before the turbocharger for trouble-free operation. The admissible values are specified in chapter Monitoring operation →43. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 41: Fig. 24: Oil Orifice

    With an oil inlet pressure of more than 3 bar of overpressure (with engine under load) up- stream of the turbocharger, the bearing casings are equipped with an orifice at the oil inlet as standard. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E...

  • Page 42: Inspection Procedures

    Make sure there is an uninterrupted supply of cooling air during opera- tion. Check whether the compressor wheel cooling is fitted on the bearing casing. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...
  • Page 43 Lubricants and pastes used during assembly can liquefy or vaporise and escape as oily fluids during the initial hours of operation. Continual escape of an oily fluid indicates an oil leak. If there is a leak, contact an ABB Turbocharging Service Station. © Copyright 2021 ABB. All rights reserved.

  • Page 44: Commissioning After Taking Out Of Operation

    Check and clean filter silencer or air supply line, and remove any foreign objects that may be present. Put engine-side oil circulation to the turbocharger into operation. Prepare the turbocharger for operation (see Checks before commissioning →40). The turbocharger is now ready for operation. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 45: Monitoring Operation

    Oil pressure measuring point Oil temperature measuring point For monitoring the lubricating oil pressure, ABB Turbocharging recommends installing a "P" manometer immediately upstream of the turbocharger oil inlet before the orifice. If the pressure is controlled electronically, the relevant signals should be triggered at the warning and alarm values.

  • Page 46: Table 7: Lubricating Oil Temperature At The Inlet

    Table 8: Maximum lubricating oil temperature at the outlet If the turbocharger has been operated for a longer period of time outside the admissible range, ABB Turbocharging recommends having the turbocharger inspected by an ABB Tur- bocharging Service Station. © Copyright 2021 ABB. All rights reserved.

  • Page 47: Exhaust Gas Temperature Before Turbine

    Definition and explanations concerning rating plate: refer to chapter 2 of Operation Manual / Safety. Operating limits: refer to chapter 3 of Operation Manual / Safety data sheet or examine rating plate. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 48: Turbocharger Speed

    42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F/I converter Plug with integrated voltage limiter 86528 Tachometer Alternative mounting position for speed sensor 32109 Sealing disc with cams © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...
  • Page 49 Check the pressure loss of the alternative air inlet and compare it with normal values. If the engine can be stopped temporarily: Inspect air lines, gas piping and the turbochargers and remedy any malfunctions. In any case, contacting the nearest ABB Turbocharging Service Station is recommended. 5.3.4 Malfunctions on the speed measurement system...

  • Page 50: Fig. 26: Replacing The Speed Sensor

    Wear safety gloves when disassembling the speed sensor. Wear safety gloves to protect against thermal hazards. The speed sensor supplied by ABB is equipped with a sealing lip and an O-ring. No additional gasket is required during assembly. Fig. 26: Replacing the speed sensor...

  • Page 51: Operation And Service

    Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 : A-weighted emission sound pressure level The enginebuilder must provide acoustically equivalent measures in case of deviating in- sulation versions © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 52: Fig. 27: Noise Insulation, Bellows

    Suggestion for noise insulation, bellows Fig. 27: Noise insulation, bellows Compressor casing Bellows Charge air duct / scavenging air duct Insulation cushion Insulation mat (at least 15 mm) Sheet metal cover © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 53: Service Work

    Agree on a specific service interval with ABB Turbocharging. To prevent machine damage caused by ageing and downtime, we recommend having an in- spection carried out by an ABB Turbocharging Service Station no later than 5 years after the last service.
  • Page 54 Service work according to data on the rating plate (Usually after 8000 … 16000 operating hours) The rotor and bearing parts must be checked and assessed by an ABB Turbocharging Service Station. The following work can be carried out as preparation.
  • Page 55 Speed of the turbocharger ¡ Air temperature after the compressor and after the charge-air cooler ¡ Exhaust gas temperature before and after the turbine ¡ Pressure loss in the filter silencer. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 56: Expected Replacement Intervals

    Table 10: Expected replacement intervals = Natural Gas = Marine Diesel Oil = Heavy Fuel Oil The specified values are guideline values and not guaranteed values, see Influencing para- meters. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...
  • Page 57 ¡ Lubricating oil quality (oil filtering, oil condition, oil monitoring) ¡ Load profile (speed, pressure conditions, temperature) ¡ Number of starts/stops ¡ Unbalance of the rotor (degree of contamination). © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 58: Stopping The Engine

    – 550 °C with insulated casing – 600 °C with non-insulated casing At temperatures below the specified values, post-lubrication must be ensured until the rotors come to a standstill. ABB Turbocharging recommends post-lubrication for 10 minutes. Observe the oil pressure specified for post-lubrication (see Table 6: Lubricating oil pres-...

  • Page 59: Periodic Maintenance Work

    Table 11: Maintenance table [h] = Hours of operation If the maintenance intervals are incompatible with operation of the engine, contact ABB Turbocharging. ABB Turbocharging recommends having mechanical cleaning carried out by an ABB Tur- bocharging Service Station during the service work (see also chapter...

  • Page 60: Cleaning The Compressor During Operation

    Periodic cleaning during operation delays any major increase in contamination. The cleaning method is suitable as long as the contamination has not progressed far. Very heavily con- taminated components can no longer be cleaned using this method. In this case, ABB Tur- bocharging recommends mechanical cleaning of the contaminated components.
  • Page 61 The compressor is cleaned during operation using the wet cleaning method. This is carried out at an engine load of 50 … 85%. This cleaning method is tested and approved by ABB Turbocharging. V-engines On V-engines with several turbochargers per engine, parallel cleaning of both turbochargers is recommended.

  • Page 62: Fig. 28: Carrying Out Wet Cleaning Of Compressor

    Not more than three cleaning cycles should be conducted consecutively. Before repeating the process, continue to operate the engine for at least five minutes to ensure that all of the water is flushed out of the system. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E...

  • Page 63: Cleaning The Turbine During Operation

    Periodic cleaning during operation delays any major increase in contamination. The cleaning method is suitable as long as the contamination has not progressed far. Very heavily con- taminated components can no longer be cleaned using this method. In this case, ABB Tur- bocharging recommends mechanical cleaning of the contaminated components.
  • Page 64 Cleaning method The turbine components are cleaned during operation using the wet cleaning method. This cleaning method is tested and approved by ABB Turbocharging. The precondition for wet cleaning is that the enginebuilder approves the process and these regulations are observed.

  • Page 65: Fig. 29: Turbine Cleaning Devices

    If necessary, the engine performance must be reduced to meet these conditions. The clean- ing cycle can be started when the above conditions are fulfilled. ) External air supply for continuous blowing off of the cleaning nozzles between cleaning in- tervals. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 66: Fig. 30: Carrying Out Wet Cleaning Of Turbines

    Close the stop valve (02) after 10 minutes. Wait for 10 minutes; do not change the load during this stabilisation phase. If the cleaning result is unsatisfactory or there is water leakage, contact an ABB Turbochar- ging Service Station. Parameter for 1-nozzle cleaning...

  • Page 67: Cleaning Components Mechanically

    The disassembly and assembly of the parts is described in the respective Disassembly and Assembly chapters. Contaminated water and cleaning agents must be disposed of in an environmentally compatible, professional way and in compliance with locally applicable regulations. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 68: Fig. 31: Cleaning The Filter Silencer

    Rinse in cold water. Avoid high mechanical loads (water jet). Let the filter ring dry completely before assembling. Dirty water and mild detergent must be disposed of in compliance with locally applicable regulations. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...
  • Page 69 When cleaning, note that the absorption segments (81136) must only be cleaned lightly with compressed air, a soft brush or a moist cleaning cloth. Have any heavily contaminated absorption segments replaced by an ABB Turbocharging Service Station. Fitting the filter silencer (see Fig. 31: Cleaning the filter silencer →66)

  • Page 70: Fig. 32: Compressor Casing

    Spray cleaned surfaces with penetrating oil. Do not spray exterior surfaces of the tur- bocharger. Dispose of dirty water and cleaning agents in accordance with the information in the ma- terial safety data sheet. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 71: Fig. 33: Diffuser

    The surfaces must be flat and even. Any deformations or deteriorations of the surface caused by the cleaning process are not permitted. Have damaged diffusers replaced by an ABB Turbocharging Service Station. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E...
  • Page 72 Wear personal protective equipment (PPE) according to the material safety data sheet. Comply with local legislation. Wear safety goggles. Wear safety gloves to protect against chemical hazards. Wear a respiratory mask to protect against gases. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 73: Fig. 34: Turbine End, Non-Rotating Parts

    Water or air can be passed through the piping and into the cleaning nozzle to check whether it is blocked. When installed, the cleaning nozzle can be mechanically cleaned with a needle. Option with 6-nozzle cleaning Removing and installing 6-nozzle turbine cleaning component (optional) →144. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...
  • Page 74 Lightly spray the compressor wheel and the gap between the compressor and the bearing casing with penetrating oil. Dispose of dirty water and cleaning agents in accordance with the material safety data sheet. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 75: Fig. 35: Soaking The Turbine End

    Use only pH-neutral cleaning agents which do not attack metals. Observe safety data sheet. Fill the container (02) with soaking fluid. To shorten the soaking time, the fluid can be heated up to a maximum of 60 ºC. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...
  • Page 76 Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against mechanical hazards. Lift up the cartridge group and align it horizontally. Remove dirt manually using a soft brush or a wire brush. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...
  • Page 77 Lightly spray the turbine and the gap between the turbine and the partition wall with pen- etrating oil. Dispose of dirty water and cleaning agents in accordance with the information in the ma- terial safety data sheet. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 78: Eliminating Malfunctions

    To prevent significant loss of efficiency, specific tolerances must be fulfilled. ¡ If there is any doubt about the extent of the rubbing, contact an ABB Tur- bocharging Service Station. ¡...

  • Page 79: Malfunctions During Operation

    Turbochar- Turbine and/or nozzle ring severely con- Clean (see chapter Periodic mainten- taminated ance work →57) Rotor components or bearing damaged Contact ABB Turbocharging Service Station Engine Defects on the connected cylinders in Contact enginebuilder pulse charging Pipes Defects, such as leaks, in the exhaust...

  • Page 80: Table 23: Malfunctions During Operation - Exhaust Gas Temperature Too High

    Gas piping between engine and turbine leaking Injection mistimed Set correctly Valve control misadjusted Pipes Pipes downstream to the compressor Repair. outlet not sealed. Table 24: Malfunctions during operation – Charge air pressure too low © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 81: Table 25: Malfunctions During Operation - Charge Air Pressure Too High

    Clean (see chapter Periodic mainten- ance work →57) Table 26: Malfunctions during operation – Engine performance losses © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 82: Turbocharger Is Surging

    Gradually reduce the engine load. Have the cause clarified and remedied immediately by an ABB Turbochar- ging Service Station. Have parts assessed for damage and, if necessary, replaced by an ABB Turbocharging Service Station. Possible causes Remedy...

  • Page 83: Malfunctions When Stopping

    Bearing damaged Check clearances (see chapter Measuring clear- ance A and B →106). If clearances are outside the tolerance or if in doubt, contact an ABB Turbochar- ging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R →116).

  • Page 84: Speed Measurement System

    Table 33: Malfunction of the speed measurement system – Measured speed too low If none of the measures described above remedy the malfunction, have the speed measure- ment system checked by an ABB Turbocharging Service Station. © Copyright 2021 ABB. All rights reserved.

  • Page 85: Dismantling And Fitting, General

    ABB Turbocharging recommends having further work carried out only by trained personnel from an ABB Turbocharging Service Station. Tightening torques for assembly devices Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB must be tightened so they are tight-fitting. Oil orifice...

  • Page 86: Material Required

    Visually inspect for corrosion, cracks, deformation and wear. Damaged tools must no longer be used and must be replaced. Swivel lifting eyes Swivel lifting eyes are required for the safe lifting of loads, which are not supplied by ABB. Fig. 36: Swivel lifting eyes Product...

  • Page 87: Fig. 37: Press-Off Screws

    A dismantling screw (01) is required to dismantle and fit the cleaning nozzles, which is not supplied by ABB. Fig. 38: Dismantling screw Product Thread Length [mm] Quantity A150-M58 / 68 Table 36: Dismantling screw © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...
  • Page 88 Use assembly devices only for the described applica- tions. ¡ Lifting gear Equipment for the lifting and transporting of loads (ropes, chain block, crane). Lifting gear is not supplied by ABB. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 89: Disassembly And Assembly Concepts

    A prerequisite is that the interfaces between the alternative air inlet (filter silencer or air suc- tion branch) and the compressor casing, as well as between the turbine casing and gas out- let casing, are accessible at the engine side. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E...

  • Page 90: Fig. 40: Cartridge Concept

    A prerequisite is that the interfaces between the cartridge group and the turbine casing, as well as between the cartridge group and the compressor casing, are accessible at the engine side. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E...

  • Page 91: Fig. 41: Optional Spanner Holder

    9 Dismantling and fitting, general / 9.3 Disassembly and assembly concepts Optional spanner holder Fig. 41: Optional spanner holder ABB offers an optional spanner holder (90165) (see Dismantling and fitting, special tools for fastening strips →140) which, in the event of limited accessibility, can be used to facilitate the loosening of nuts and the application of tightening torques for the strip connection between the cartridge group and the turbine casing.

  • Page 92: Weights Of Individual Parts

    Turbine casing 1 inlet * 2 inlets * 3 inlets * Gas outlet flange Gas outlet casing with insulation Table 37: Weights of assemblies * including burst protection and insulation © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 93: Table Of Tightening Torques

    Part number A150-M58/68 72051 275 Nm 79041 8 Nm 51007 175 Nm 51007 with spanner holder (90165) 85 Nm 51009 200 Nm 72011 275 Nm 86505 M12 x 1.5 15 Nm 200 Nm Table 38: Tightening torques © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 94: Fig. 44: Tightening Torques For Insulation

    Fig. 44: Tightening torques for insulation The following tightening torques must be observed for the specified bolted connections: Position Part number A150-M58/68 200 Nm 65 Nm 10 Nm 25 Nm 45 Nm Table 39: Tightening torques for insulation © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 95: Dismantling And Fitting With Removed Air Inlet And Gas Outlet

    2. Loosen the hexagon-head screws (72051) and remove them with fastening strips (72012). 3. Remove the filter silencer (81000) or air suction branch (82000). 4. Remove and dispose of the O-ring (81010 or 82010). © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 96: Removing The Gas Outlet Casing

    4. Loosen and remove nuts (51009). 5. Remove the gas outlet casing (61001), set it down properly in an appropriate place and secure it. 6. Remove and dispose of the gasket (61002). © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 97: Fig. 47: Removing Gas Outlet Casing With Support 1

    4. Remove fixing screws of support (61301) to bracket. 5. Fit swivel lifting eyes (S) to the gas outlet casing (61001). Attach lifting gear to swivel lift- ing eye and secure to a crane hook. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E...

  • Page 98: Fig. 48: Removing Gas Outlet Casing With Support 1

    6. Loosen nuts (51009) and remove together with support (61301). 7. Remove the gas outlet casing (61001), set it down properly in an appropriate place and secure it. 8. Remove and dispose of the gasket (61002). © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 99: Removing The Gas Outlet Flange

    M58/68 Table 40: Press-off screws – gas outlet flange * not included in the ABB scope of delivery. 1. Evenly press off and remove the gas outlet flange (57002) with screws (01) according to the table. If the gas outlet flange cannot be pressed off with the maximum tightening torque, contact an ABB Turbocharging Service Station.

  • Page 100: Removing The Cartridge Group With Compressor And Turbine Casing

    (01) must not be loosened during disassembly. Fig. 51: Remove insulation 2. Remove the compressor casing insulation. 3. Remove the turbine casing insulation. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 101: Fig. 52: Removing The Cartridge Group With Compressor And Turbine Casing

    10. Turn the compressor and turbine casing and set down on suitable supports. 11. Remove lifting gear from cartridge group. Leave second lifting gear attached to com- pressor casing for safety. 12. Remove and dispose of the O-rings (42195, 42200). © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 102: Removing The Compressor Casing

    Mark the casing position for assembly. Fig. 54: Removing the compressor casing Disc as scratch protection (not included in the ABB scope of delivery) If the compressor casing cannot be loosened, it can be pressed off against the turbine cas- ing with the press-off tool (90042/90022).

  • Page 103: Removing The Cartridge Group

    1. Treat threads of studs (51006) with penetrating oil and leave to take effect. 2. Loosen nuts (51007) and remove Verbus Ripp® washers (51003) together with the fasten- ing strips (51002). 3. Fit the cross-piece of the service support (90012). Observe the tightening torque. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 104: Fig. 56: Removing Cartridge Group 2

    6. Remove the cartridge group vertically from the turbine casing. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E...

  • Page 105: Fig. 57: Removing Cartridge Group 3

    7. Place a suitable protective cover over the compressor wheel. 8. Turn the cartridge group into the horizontal rotor axis. 9. Remove lifting gear from service support and cross-piece. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 106: Installing The Cartridge Group On The Service Support

    Fig. 58: Installing the cartridge group on the service support 1. Assemble the service support (90012) with longitudinal and cross-pieces. 2. Fit service support to cartridge group. 3. Put down cartridge group. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 107: Removing The Nozzle Ring

    Removing the nozzle ring Fig. 59: Removing the nozzle ring 1. Pull out the nozzle ring (56001) with the two extraction devices (90070). 2. Remove the lamellar sealing ring (56005). © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 108: Measuring Clearance A And B

    Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2021 ABB. All rights reserved.

  • Page 109: Nozzle Ring Compression Pd

    Table 43: Nozzle ring compression PD 1. Measure values A, B, and S on cleaned surfaces. 2. Calculate compression (PD). If the calculated value (PD) lies outside the specified range, contact an ABB Turbochar- ging Service Station. © Copyright 2021 ABB. All rights reserved.

  • Page 110: Installing Nozzle Ring

    (see detail B). 2. Align the cams on the nozzle ring with the recesses of the turbine casing (51000). 3. Insert the nozzle ring (56001) into the turbine casing up to the stop. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E...

  • Page 111: Installing The Cartridge Group

    Fig. 63: Lifting the cartridge group and rotating it by 90° 1. Fasten lifting gear to cartridge group and lift cartridge group. 2. Remove service support (90012). 3. Dismantle service support. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 112: Fig. 64: Turning The Cartridge Group

    7. Turn the cartridge group into the vertical position of the rotor axis. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E...

  • Page 113: Fig. 65: Installing The Cartridge Group

    9. Align casing position of cartridge group with marking and lower into the turbine casing. 10. Remove lifting gear cross-piece of service support. 11. Install the fastening strips (51002) with Verbus Ripp® washers (51003) and hexagon nuts (51007). Observe the tightening torque. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 114: Installing The Compressor Casing

    1. Secure the diffuser (79000) with fixing discs (79040) and new screws (79041). Observe the tightening torque. 2. Fit lifting gear with swivel lifting eye (S) to compressor casing (72000) and rotate the compressor casing by 180°. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 115: Fig. 67: Installing The Compressor Casing

    Table 47: Tightening torque (72011) 1. Fit new O-ring (42012). 2. Thoroughly clean the fastening strips (72012) before assembly. 3. Install the compressor casing (72000). 4. Install the fastening strips (72012) with screws (72011). Observe the tightening torque. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 116: Turning The Cartridge Group With Compressor And Turbine Casing

    2. Lift cartridge group with compressor and turbine casing with the first lifting gear and lower it with the second lifting gear. 3. Remove second lifting gear and swivel lifting eye. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E...

  • Page 117: Installing The Gas Outlet Flange

    2. Fit swivel lifting eye (S) to the gas outlet flange (57002). Secure lifting gear to the swivel lifting eye. 3. Install gas outlet flange in turbine casing (51000). 4. Measure radial clearance (R) (see chapter Radial clearances N and R). © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 118: Radial Clearances N And R

    Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2021 ABB. All rights reserved.

  • Page 119: Fitting The Insulation

    10 Dismantling and fitting with removed air inlet and gas outlet / 10.17 Fitting the insulation 10.17 Fitting the insulation Fig. 71: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see Table of tightening torques →91). © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 120: Installing The Cartridge Group With Compressor And Turbine Casing

    5. If present: Remove the screw plug from the connection for the compressor wheel cooling (01) and fit the cooling air line. 6. If present: Plug in the plug to the speed sensor (86505). If present: Fit connecting pipe for turbine cleaning. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 121: Installing The Gas Outlet Casing

    5. Fit hexagon nuts (51009). Observe the tightening torque. →91). 6. Fit insulation ring. Observe tightening torques (see Table of tightening torques 7. If present: Attach waste gate pipe. Tighten in accordance with enginebuilder’s specifica- tions. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 122: Fig. 75: Installing Gas Outlet Casing With Support 1

    3. Fit swivel lifting eyes (S) to gas outlet casing (61001). Secure lifting gear to the swivel lift- ing eye. 4. Place gas outlet casing on the turbine casing (51000). Observe the marking. 5. Fit support (61301). 6. Fit hexagon nuts (51009). Observe the tightening torque. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 123: Fig. 76: Installing Gas Outlet Casing With Support 2

    Table of tightening torques →91). 9. Fit gas outlet casing insulation (see Table of tightening torques →91). 10. If present: Attach waste gate pipe. Tighten in accordance with enginebuilder’s specifica- tions. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 124: Installing Air Inlets

    2. Fit a new O-ring (81010) to the filter silencer (81000) or a new O-ring (82010) to the air suction branch (82000). 3. Install the filter silencer (81000) or air suction branch (82000). 4. Fit the fastening strips (72012) with hexagon-head screws (72051). Observe the tighten- ing torque. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 125: Dismantling And Fitting, Cartridge Concept

    2. Loosen the hexagon-head screws (72051) and remove them with fastening strips (72012). 3. Remove the filter silencer (81000) or air suction branch (82000). 4. Remove and dispose of the O-ring (81010 or 82010). © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 126: Fig. 79: Removing The Compressor Casing

    2. Fit swivel lifting eye (S) to the compressor casing (72000). Secure lifting gear to the swivel lifting eye. 3. Loosen screws (72011) and remove together with fastening strips (72012). 4. Remove the compressor casing (72000). © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 127: Fig. 80: Pressing Off Compressor Casing

    (90042/90022). Fig. 80: Pressing off compressor casing Disc as scratch protection (not included in the ABB scope of delivery) 1. Remove front turbine casing insulation. 2. Press off compressor casing with press-off tool (90042/90022) and disk (01).

  • Page 128: Fig. 82: Removing Insulation Sheets

    3. Loosen the clamping nut (42201) (see Loosening the clamping nut →31). 4. Use the hexagon to raise the threaded rod (42191) up to its stop. 5. Attach lifting gear to cartridge group. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 129: Fig. 84: Removing Cartridge Group 2

    1. Treat threads of studs (51006) with penetrating oil and leave to take effect. 2. Loosen nuts (51007) and remove Verbus Ripp® washers (51003) together with fastening strips (51002). 3. Pull the cartridge group from the turbine casing and remove it. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 130: Fig. 85: Removing Cartridge Group 3

    1. Unscrew the threaded stud (42191) downwards and remove the clamping nut (42201). 2. Remove and dispose of the O-rings (42195, 42200). 3. If present: Remove the metal C-ring (51105). 4. Attach the cartridge group to the service support (90012). © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 131: Fig. 86: S_05180

    11.4 Removing the nozzle ring Fig. 86: S_05180 1. Pull out the nozzle ring (56001) with the two extraction devices (90070). 2. Remove the lamellar sealing ring (56005). © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 132: Fig. 87: Measuring Clearance A And B

    Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2021 ABB. All rights reserved.

  • Page 133: Fig. 88: Nozzle Ring Compression Pd

    Table 53: Nozzle ring compression PD 1. Measure values A, B, and S on cleaned surfaces. 2. Calculate compression (PD). If the calculated value (PD) lies outside the specified range, contact an ABB Turbochar- ging Service Station. © Copyright 2021 ABB. All rights reserved.

  • Page 134: Fig. 89: Installing The Nozzle Ring

    (see detail B). 2. Align the cams on the nozzle ring with the recesses of the turbine casing (51000). 3. Insert the nozzle ring (56001) into the turbine casing up to the stop. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E...

  • Page 135: Fig. 90: Installing The Cartridge Group

    3. Screw the threaded stud (42191) into the clamping nut (42201) from below as far as its stop. 4. Fit new O-rings (42195, 42200). 5. If present: Insert the metal C-ring (51105). © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 136: Fig. 91: Installing The Cartridge Group 2

    3. Tighten pressure screws of clamping nut (see chapter Fastening the turbocharger with a clamping nut →35). 4. Secure fastening strips (51002) together with nuts (51007) and Verbus Ripp® wash- ers (51003). © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 137: Fig. 92: Fitting The Diffuser

    1. Secure the diffuser (79000) with fixing discs (79040) and new screws (79041). Observe the tightening torque. 2. Fit lifting gear with swivel lifting eye (S) to compressor casing (72000) and rotate the compressor casing. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 138: Fig. 93: Installing The Compressor Casing

    Table 57: Tightening torque (72011) Thoroughly clean the fastening strips (72012) before assembly. 1. Fit a new O-ring (42012). 2. Install the compressor casing (72000). 3. Install the fastening strips (72012) with screws (72011). Observe the tightening torque. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 139: Fig. 94: Measuring Clearances N And R

    Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2021 ABB. All rights reserved.

  • Page 140: Fig. 95: Fitting The Insulation

    11 Dismantling and fitting, cartridge concept / 11.11 Fitting the insula- tion 11.11 Fitting the insulation Fig. 95: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see Table of tightening torques →91). © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 141: Fig. 96: Installing The Air Inlets

    2. Fit a new O-ring (81010) to the filter silencer (81000) or a new O-ring (82010) to the air suction branch (82000). 3. Install the filter silencer (81000) or air suction branch (82000). 4. Fit the fastening strips (72012) with hexagon-head screws (72051). Observe the tighten- ing torque. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 142: Dismantling And Fitting, Special Tools For Fastening Strips

    Dismantling and fitting, special tools for fastening strips ABB offers an optional special tool set (90160) which, in the event of limited accessibility, can be used to facilitate the loosening of nuts and the application of tightening torques for the strip connection between the cartridge group and the turbine casing.

  • Page 143: Application, Special Tools

    4. Remove the nuts (51007) with spanner holder (90165/90166) and attached torque span- ner (02). Remove washers (51003) and fastening strips (51002). Any falling screw material will be caught in the collection tub (01). © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E...

  • Page 144: Fig. 100: Fitting The Upper Fastening Strips

    2. Position the collection tray (01) to catch any fixing elements if they fall. 3. Tighten the two nuts on one side using the spanner holder (90165). 4. Tighten the two nuts on the other side using the spanner holder (90166). © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E...

  • Page 145: Fig. 102: Fitting The Bottom Fastening Strip

    Tightening torque [Nm] A150-M58/68 Table 62: Tightening torque (51007) with spanner holder 5. Fit the nuts (51007) with spanner holder (90165 / 90166) and attached torque span- ner (02). Observe the tightening torque. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 146: Removing And Installing 6-Nozzle Turbine Cleaning Component (Optional)

    Fig. 104: Disassembly of the elbows 1. Just loosen the union nuts (51316) of the elbows (51311). Do not remove them yet. 2. Just loosen the screws (51314). Do not remove them yet. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E...

  • Page 147: Fig. 105: Disassembly Of The Elbows

    Remove the elbows (51311) from the connecting pieces (51313) in the specified order (01, 02, 03, 04, 05). Fig. 106: Pipe disassembly 1. Undo union nuts (51316) of pipe (51312). 2. Remove pipe. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 148: Fig. 107: Disassembly Of The Connecting Pieces

    Fig. 108: Disassembly of the cleaning nozzle Remove cleaning nozzles (51301) with screw (01) in accordance with the following table. Product Thread Length [mm] Quantity A150-M58 / 68 Table 63: Dismantling screw © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 149: Assembly

    2. Position connecting pieces (51313). 3. Position gaskets (51302) on connecting pieces (51313). 4. Coat thread and contact surfaces of hexagon-head screws (51314) with high-temperat- ure grease. Tighten screws by hand only. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 150: Fig. 111: Pipe Assembly

    Coat thread and contact surfaces of cutting ring with high-temperature grease. Screw union nuts (51316) of elbows (51311) in the specified order (01, 02, 03, 04, 05) to the connecting pieces (51313). © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E...

  • Page 151: Fig. 113: Elbow 2 Assembly

    Fig. 113: Elbow 2 assembly Product 51314 [Nm] 51316 [Nm] A150-M58/68 Table 65: Tightening torque (51314 / 51316) 1. Tighten hexagon-head screws (51314) to tightening torque. 2. Tighten union nuts (51316) of elbows (51311) to tightening torque. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 152: Fitting The Cleaning Nozzles With Multi-Inlet Turbine Casings

    1. The designation (P . ) on the turbine casing must correspond with the designation (P . ) on the cleaning nozzle. 2. The edges for the defined installation position in the turbine casing and at the cleaning nozzle must correspond. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 153: Taking Out Of Operation At Short Notice

    ¡ If a replacement turbocharger or cartridge group is not available: Fit cover plate →153 and contact an ABB Turbocharging Service Station. Observe the following sections in connection with the emergency repairs mentioned. © Copyright 2021 ABB. All rights reserved.

  • Page 154: Installing The Replacement Turbocharger

    The repair of a cartridge group requires special tools and the expertise of an ABB Turbochar- ging Service Station. The rotating parts rotate extremely quickly, and are sensitive to unbal- ance.

  • Page 155: Fitting The Cover Plate

    3. Coat the threads of the studs (51006) with high-temperature grease. 4. Fasten cover plate (01) to turbine casing (51000) with fastening strips (51002), Verbus Ripp® washers (51003) and nuts (51007) and screw to bracket. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E...

  • Page 156: Cover Plate Drawing

    15 Taking out of operation at short notice / 15.5 Cover plate drawing 15.5 Cover plate drawing The cover plate is not included in the ABB scope of delivery and must be manufactured by the operating company according to the following drawing. Material: General structural steel, in accordance with DIN EN 10025-2.

  • Page 157: Fig. 117: Dimensions For Cover Plate

    15 Taking out of operation at short notice / 15.5 Cover plate drawing Fig. 117: Dimensions for cover plate Product D2 ± 0.1 A150 90 ± 0.2 28.2 Table 67: Cover plate dimensions [mm] © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 158: Mothballing The Turbocharger

    If the acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking the engine out of operation: Dismantle the turbocharger. The rotor and bearing parts must be dismantled and subsequently refitted by an ABB Tur- bocharging Service Station. Clean all parts.

  • Page 159: Taking The Engine Out Of Operation For More Than 12 Months

    ¡ The casings of the turbocharger remain attached to the engine, the rotor and bearing parts are dismantled by an ABB Turbocharging Service Station and stored separately ¡ The turbocharger is completely removed, either as a whole unit or in individual parts For the measures always necessary for preparing the turbocharger parts for mothballing, see section Taking the engine out of operation for up to 12 months, subsection Preparations...

  • Page 160: Disposing Of Turbocharger Components

    Dispose of metals as scrap metal for recycling. Dispose of non-metallic materials as waste. Dispose of residues of lubricants as waste oil. Dispose of electronic components as electronic waste. Dispose of thermal insulation as hazardous waste. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 161: Spare Parts

    79041 Counter-sunk screw 81010 / 82010 O-ring Table 68: Customer spare part set 97070 * This gasket can only be installed if a gas outlet casing from ABB is used. © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 162: Spare Part - Illustrations

    Cartridge 42012* O-ring 42047 Screw plug 42166 Screw 42167 Cover 42170 Insulation 42172 Hexagon-head screw 42188 Hexagon-head screw 42189 Gasket 42190** Expansion bush 42191 Threaded rod 42193** Centering bush © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 163: Table 69: Spare Parts - Cartridge, Oil Cooled

    18 Spare parts / 18.3 Spare part – Illustrations Part no. Designation 42194 Gasket 42195* O-ring 42196 Orifice oil inlet 42197 Safety-ring 42200* O-ring 42201 Clamping nut 42202 Screw plug Table 69: Spare parts - Cartridge, oil cooled © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 164: Table 70: Spare Parts - Bearing, Casing Oil Cooled

    Hexagon-head screw 42020* Washer 42301 Bearing cover 42302* Piston ring 42303* Piston ring 42305* O-ring 42306* O-ring 42308* O-ring 42400 Heat shield Table 70: Spare parts - Bearing, casing oil cooled © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 165: Table 71: Spare Parts - Rotor And Bearing Parts

    Bearing flange 32113* Socket screw 32114* Socket screw 32159* Socket screw 32167* ** Snap ring 42002 Socket screw 42302* Piston ring Table 71: Spare parts - Rotor and bearing parts © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 166: Table 72: Spare Parts - Turbine Casing, 1 Inlet

    Tension washer 51500 Burst protection 56001 Nozzle ring 56005 Lamellar sealing ring 57002 Gas-outlet flange 57003(o) Metal C-ring 57210 Burst ring Table 72: Spare parts – Turbine casing, 1 inlet © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 167: Table 73: Spare Parts - Turbine Casing, 2 Inlets

    Tension washer 51500 Burst protection 56001 Nozzle ring 56005 Lamellar sealing ring 57002 Gas-outlet flange 57003** Metal C-ring 57210 Burst ring Table 73: Spare parts – Turbine casing, 2 inlets © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 168: Table 74: Spare Parts - Turbine Casing, 3 Inlets

    Screw plug 51500 Burst protection 56001 Nozzle ring 56005 Lamellar sealing ring 57002 Gas-outlet flange 57003** Metal C-ring 57210 Burst ring Table 74: Spare parts – Turbine casing, 3 inlets © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 169: Table 75: Spare Parts - Cleaning Device

    51309 Expansion sleeve 51310 Hexagon nut 51311 Pipe elbow 51312 Pipe 51313 Joining piece 51314* Hexagon-head screw 51316 Cap nut 51317 Stop plug Table 75: Spare parts - Cleaning device © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 170: Table 76: Spare Parts - Gas Outlet Casing, Radial

    Gas-outlet casing 61002* Gasket 61005(p) Screw plug 61100 Insulation gas-outlet casing GW03 61140 Insulation 61201 Hexagon-head screw 61202 Tension washer 61301** Support Table 76: Spare parts - Gas outlet casing, radial © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 171: Table 77: Spare Parts - Compressor Casing

    Insulation sleeve 72062 Hexagon-head screw 72063 Tension washer 77000 Wall insert 77005* O-ring 77006 Stud 79000 Diffuser 79040 Fixing washer 79041* Counter-sunk screw Table 77: Spare parts - Compressor casing © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...
  • Page 172 Absorption segment 81137 Cover sheet-metal 81145 Flange compressor-end 81146 Flange turbine-end 81147 Fixing ring 81148 Damping element 81149 Holding sheet metal 81150 Clamping strap 81151 Spring-type pin 81152 Hexagon-head screw © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 173: Table 78: Spare Parts - Filter Silencer

    HZTL443474 Mod. A Part no. Designation 82000 Air suction branch 82005 Screw plug 82006 Gasket 82007 Screw plug 82008 Gasket 82010* O-ring Table 79: Spare parts - Air suction branch axial © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 174: Table 80: Spare Parts - Air Suction Branch Radial

    HZTL443315 Mod. B Part no. Designation 82000 Air suction branch 82005 Screw plug 82006 Gasket 82007 Screw plug 82008 Gasket 82010* O-ring Table 80: Spare parts - Air suction branch radial © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 175: Table 81: Spare Parts - Speed Measurement System

    86515** 86505** ** = if provided HZTL443475 Mod. A Part no. Designation 86258** Tachometer 86505** Speed sensor 86515** Cable connector 86526** F/I-Converter Table 81: Spare parts - Speed measurement system © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Rev.E January 2021...

  • Page 176: Tools

    Extraction device Table 82: Customer tool set 90000 ABB offers an optional special tool set (90160) which, in the event of limited accessibility, can be used to facilitate the loosening of nuts and the application of tightening torques for the strip connection between the cartridge group and the turbine casing.
  • Page 177 Operation Manual / A150-M58/68 19 Tools / ​ Tool sets can be ordered from any ABB Turbocharging Service Station. The following spe- cifications must be included in the order: ¡ Turbocharger type ¡ Designation and part number of the tool set.
  • Page 178 Fig. 59: Removing the nozzle ring......105 Fig. 30: Carrying out wet cleaning of turbines ..64 Fig. 60: Measuring clearance A and B ...... 106 Fig. 31: Cleaning the filter silencer ......66 © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Revision E January 2021...
  • Page 179 Fig. 87: Measuring clearance A and B ..... 130 Fig. 88: Nozzle ring compression PD ....... 131 Fig. 89: Installing the nozzle ring......132 Fig. 90: Installing the cartridge group ....133 Fig. 91: Installing the cartridge group 2....134 © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Revision E January 2021...
  • Page 180 .......... 78 Table 52: Permissible clearances A and B ....130 Table 24: Malfunctions during operation – Charge air pressure too low............78 Table 53: Nozzle ring compression PD ..... 131 © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Revision E January 2021...
  • Page 181 Table 80: Spare parts - Air suction branch radial.. 172 Table 81: Spare parts - Speed measurement system.. Table 82: Customer tool set 90000 ......174 Table 83: Special tool (90160)........174 © Copyright 2021 ABB. All rights reserved. HZTL4041_EN Revision E January 2021...

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