ABB HT564586 Operation Manual
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ABB HT564586 Operation Manual

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Operation Manual
A175-L37
HT564586 English
Original Operation Manual
Chapter
1
Introduction
2
Safety
3
Safety data sheet
4
Product description
ABB Turbocharging
Document-ID
HZTL4005_EN_E
HZTL4024_EN_C
HT564586
HZTL4034_EN_F

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  • Page 1 Operation Manual A175-L37 HT564586 English Original Operation Manual Chapter Document-ID Introduction HZTL4005_EN_E Safety HZTL4024_EN_C Safety data sheet HT564586 Product description HZTL4034_EN_F ABB Turbocharging...
  • Page 2 Operating limits and replacement intervals The recommended replacement intervals and the corresponding operating limits in chapter 3 are jointly defined with the enginebuilder. This information is specific to the product. Non-observance of the recommended replacement intervals and the operating limits increases the risk of unpre- dictable component failures.

  • Page 3: Table Of Contents

    Table of contents Page 1 / 8 Introduction Introduction .................... Purpose of the manual ................Symbols, definitions ................... Storage of new turbochargers and spare parts .......... Contact information ..................© Copyright 2016 ABB. All rights reserved. HZTL4005_EN Revision E July 2016...

  • Page 5: Introduction

    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 2016 ABB. All rights reserved. HZTL4005_EN Revision E July 2016...

  • Page 6: Symbols, Definitions

    Official service stations of ABB Turbo Systems Official service stations are identified in this document as ABB Turbocharging Service Sta- tions. They are regularly audited and certified by ABB Turbo Systems. Also see chapter Con- tact information [➙ 8]. © Copyright 2016 ABB. All rights reserved.
  • Page 7 Dispose of in an environmentally with specifications compatible, professional way and in compliance with locally applica- Oil free, grease free and dry ble regulations. Table 1: Definition of pictograms © Copyright 2016 ABB. All rights reserved. HZTL4005_EN Revision E July 2016...

  • Page 8: Storage Of New Turbochargers And Spare Parts

    Old VCI corrosion protection emitters must be disposed of in an environmentally compati-  ble, professional way and in compliance with locally applicable regulations. Close package. The more tightly the package is sealed, the longer the protection duration.  © Copyright 2016 ABB. All rights reserved. HZTL4005_EN Revision E July 2016...
  • Page 9 Check the package for damage. If the package is damaged, the turbocharger or cartridge  group must be checked and repackaged by an ABB Turbocharging Service Station. After every 3 years, the following steps must be carried out by an ABB Turbocharging Service Station:  Checking the component ...

  • Page 10: Contact Information

    Operation Manual / 1 Introduction Introduction Page 8 / 8 Contact information Contact information of the ABB Turbocharging Service Stations is available online. Scan the QR code to access our website.  ABB Turbo Systems Ltd Bruggerstrasse 71a CH-5401 Baden Switzerland www.abb.com/turbocharging...
  • Page 11 Periodic check of the pressure vessels ............Lifting of loads ..................... 1.10 Prerequisites for operation and maintenance ..........1.11 Hazards during operation and maintenance ..........1.12 Safe operation ..................... 1.13 Safe maintenance ..................HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...

  • Page 13: 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. Nev- ertheless, there may be some residual risks during operation of and work on the turbocharger which: ...

  • Page 14: Definition Of Mandatory Signs

    CAUTION can lead to serious CAUTION damage to engine or property with grave consequences. Caution signs must always be observed.  HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...

  • Page 15: Intended Use

    The specific operating limits of the turbocharger were determined on the basis of information from the enginebuilder about the intended use. These data are given on the rating plate. ABB accepts no liability and rejects all warranty claims for any non-intended uses. Unapproved operation Any operation of the turbocharger outside of its operating limits can be haz- ardous to personnel.

  • Page 16: Warning Plates On The Turbocharger

    Manual, Chapter 4 Product description. Turbochargers supplied to the enginebuilder without insulation must be equipped later with warning plates on the insulation. This is the responsibility of the enginebuilder. HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...

  • Page 17: Turbocharger Rating Plate

    06 Customer part number 07 Designation for special design 08 Weight of turbocharger in kg 09 Turbocharger type 10 Serial number 11 Year of construction of turbocharger 12 Manufacturing plant HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...

  • Page 18: 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".  The locally applicable legal regulations regarding periodic checks of the pressure vessels must be observed.

  • Page 19: Lifting Of Loads

    The assembly devices must be completely screwed in and must not unscrew 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. HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...

  • Page 20: Prerequisites For Operation And Maintenance

    WARNING personnel. Only use original parts from ABB Turbo Systems.  ABB accepts no liability for any damage resulting from the use of non-original parts and corre- sponding accessories. HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved.

  • Page 21: Hazards During Operation And Maintenance

    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. HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...
  • Page 22 At the same time, electrical or electronic components and parts can also be damaged or destroyed. Only specially trained personnel should perform work on, or with, electri-  cal components. Observe national regulations.  HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...

  • Page 23: Safe Operation

    When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay  attention to the risks that may occur as a consequence of this energy input. HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...

  • Page 24: Safe Maintenance

    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.  HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...
  • Page 25 Secure rotor against turning. The rotor can rotate due to the stack draught alone.  Observe the material safety data sheet for the cleaning and mothballing agents.  Wear personal protective equipment (PPE) according to the material safety data sheet.  HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...
  • Page 26  ty 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. HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...
  • Page 27  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. HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...
  • Page 29 Operation Manual / A175-L37 / Safety data sheet Page 1 / 1 Safety data sheet A175-L37 HT564586 A175-L37 HT564586 5600 2016 © Copyright 2016 ABB. All rights reserved. HT564586 September 2016...
  • Page 31 Foreword to maintenance ................Cleaning the filter silencer ................Changing the filter strip on the filter silencer casing ........Cleaning the compressor during operation ..........Cleaning the turbine during operation ............© Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 32: Table 15 Malfunctions When Starting

    Taking the engine out of operation for up to 12 months ......10.2 Taking the engine out of operation for more than 12 months ...... 100 Disposing of turbocharger components ............ Spare parts ..................... © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 33 Page 3 / 111 12.1 Ordering spare parts .................. 103 12.2 View of turbocharger with part numbers ............. 12.3 View of cartridge group with part numbers ..........Figures ....................Tables ....................© Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 35: Introduction

    This document is valid for different turbocharger design variants. As a result, it might contain sections and descriptions of components that do not apply to a certain turbocharger. If you have any queries about a design variant, ABB Turbocharging Service Stations will be pleased to provide information (see Contact information at www.abb.com/turbocharging).

  • Page 36: Layout And Function Of The Turbocharger

    03 Radial plain bearing 10 Diffuser 04 Radial plain bearing 11 Compressor wheel 05 Gas outlet casing 12 Compressor casing 06 Turbine wheel 13 Air-outlet silencer (option) 07 Nozzle ring © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 37 This oil tank supplies the bearings of the rotor with oil until standstill in the event that a mal- function of the lubrication oil system causes an emergency stop of the engine. © Copyright 2016 ABB. All rights reserved. HZTL4034_EN...

  • Page 38: Warning Plates On The Turbocharger

    Figure 2: Warning plate locations If warning plates are not present in the designated locations or not readable, proceed as fol- lows: Order new warning plates from ABB Turbocharging Service Stations.  Remove any warning plates that have become unreadable.

  • Page 39: Locations Of The Rating Plates

    Locations of the rating plates Figure 3: Locations of the rating plates One rating plate (01) each is attached on the left and the right side of the turbocharger bearing casing. © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 41: Removal And Installation

    Disconnect all pipes according to the instructions of the enginebuilder.  Check lifting gear.  Fasten lifting gear on suspension eyes of the bearing casing and tauten.  © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 42 Figure 4: Fitting lifting gear to turbocharger Loosen fixing screws on compressor-end and turbine-end foot.  Lift turbocharger from engine and put down in a suitable location.  Cover oil connections.  © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 43: Installing The Turbocharger

    Remove lifting gear from suspension eyes of the bearing casing.  Connect cable to speed sensor.  Connect all gas, air and oil pipes.  © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 44: Table 3 General Information About Fastening The Turbocharger

    Tighten the foot fixing screws or nuts diagonally according to the selected tightening method.  Turbine-end foot Figure 7: Turbine-end foot Tighten the foot fixing screws or nuts according to the selected tightening method.  © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 45: Table 4 Tightening Torques

    Table 5: 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. © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 47: Commissioning

    Inspection procedures include preventative visual controls, monitoring and measuring work before and during commissioning. Inspection procedures enable changes to the turbocharger to be detected. Engine damage can be prevented. © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 48 The admissible values are specified in section Oil supply. Gas, air and oil pipes After starting the engine, check all gas, air and oil pipes for leaks.  © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 49: Commissioning After Taking Out Of Operation

    Continuous escape of NOTICE an oily fluid indicates an oil leak. If there is a leak, contact an ABB Turbocharging Service Station. Commissioning after taking out of operation If present Remove cover plates (blind flanges) on the compressor casing, on the gas-inlet as well as ...

  • Page 51: Monitoring During Operation

    Not admissible → stop engine > 90 Not admissible → do not start engine (before start: preheat oil) < 30 Table 7: Lubricating oil temperature at the inlet © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 52: Table 8 Lubricating Oil Temperature At The Outlet

    Table 8: Lubricating oil temperature at the outlet If the turbocharger was operated for a longer period of time outside of the admissible range, ABB Turbo Systems recommends to have the turbocharger inspected by an ABB Turbocharg- ing Service Station.

  • Page 53: Turbocharger Speed

    86506 O-ring 42047 Screw plug 86515 Cable connector 32109 Sealing disc with cams 86526 F/I converter Alternative mounting position for speed sensor or for the second speed sensor © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 54 If the engine can be stopped temporarily: Inspect air lines, exhaust gas pipes and the turbochargers and remedy any malfunctions.  ABB Turbo Systems recommends contacting the nearest ABB Turbocharging Service Sta-  tion. © Copyright 2016 ABB. All rights reserved.
  • Page 55 Screw in new speed sensor to the stop.  Connect cable connector (86515) with the speed sensor (86505)  Switch on lubricating oil supply to the turbocharger.  © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 56 Monitoring during operation Page 26 / 111 4.2.5 Malfunction of the speed measurement system The possible reasons for malfunction of the speed measuring system are described in chapter Troubleshooting. © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 57: Low Pressure Measurement At The Filter Silencer

    NOTICE Better readability of the U-tube manometer can be achieved by filling with slightly coloured water. © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 59: 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 insula- tion versions © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 60: Service Work

    Service work on the turbocharger that are omitted or performed too late can cause excessive contamination, wear and operating failures. CAUTION Carry out the service work at the specified time intervals.  © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 61 Agree on a shortened service interval with ABB Turbo Systems.  5-year service inspection To prevent machine damage caused by ageing and downtime, we recom- mend having an inspection carried out by an ABB Turbocharger Service Sta- NOTICE tion no later than 5 years after the last service. 5.2.1 Service procedures every 25 …...
  • Page 62 Operation and service Page 32 / 111 5.2.3 Service work on turbocharger every 18000 hours It is recommended to have service work and checks carried out by an ABB Turbocharging Service Station. Remove the filter silencer.  Clean filter silencer and check for damage.
  • Page 63  Lubricating oil pressure and lubricating oil temperature  Pressure loss in the filter silencer Air temperature after the charge air cooler  If present:  Air temperature after the compressor © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 64: Expected Replacement Intervals

    See rating plate data Bearings See rating plate data Table 11: Recommended replacement intervals for turbocharger parts The specified values are guideline values and not guaranteed values, see Influencing parame- ters. © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 65: Flexible Turbocharger Cut-Out

    The air outlet flap and gas inlet flap must be completely open during nor-  mal operation. During cut out operation, the air outlet flap and gas inlet flap must be  completely closed. © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 66: Stopping The Engine

    500 hours of operation. NOTICE Stopping the engine Observe the instructions regarding post-lubrication (Pre-lubrication and post-lubrication [➙ 22])  Stop the engine.  © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 67: Periodic Maintenance

    Maintenance work includes regular visual controls and cleaning operations which are intended to ensure the trouble-free functioning of the turbocharger. Described maintenance points:  Filter silencer  Compressor  Turbine and nozzle ring © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 68: Cleaning The Filter Silencer

    Body of filter silencer 81268 Connecting strip 81136 Absorption segment 81270 Tension band 81137 Sheet-metal covering 81271 Lock 81265 Filter ring (if present) Insert unit (absorption segment / sheet-metal covering fitted) © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 69 Replace heavily contaminated absorption segments (81136) and any damaged connecting  strips (81268) with original parts from ABB Turbo Systems. Fitting the filter silencer Insert the absorption segments (81136) into the sheet-metal coverings (81137).

  • Page 70: Changing The Filter Strip On The Filter Silencer Casing

    Figure 13: Dismantling filter ring circumferential part Dismantle circumferential part (9).  Figure 14: Opening filter ring lock Open the lock of the filter ring (81265).  © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 71 Pull on the old filter ring until the new filter ring is completely wrapped around the filter  silencer. Undo the connection between the new and the old filter ring.  Fasten the newly installed filter ring (81265), then fit circumferential part (9).  © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 72: Cleaning The Compressor During Operation

    The interval between the cleaning cycles depends greatly on the operating conditions. Clean- ing should normally take place about every 50 hours of operation. If the specified cleaning intervals are incompatible with operation of the engine, contact ABB Turbo Systems.
  • Page 73 Volume of water for cleaning the compressor Uncontrolled volumes of water can damage the turbocharger and the en- gine. CAUTION Do not guide water pipes to the filler openings.  © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 74 Repeating the cleaning If the cleaning is still unsuccessful after three processes, it is recommended to have the turbo- charger checked and cleaned by an ABB Turbocharging Service Station if the engine values are unsatisfactory. © Copyright 2016 ABB. All rights reserved.

  • Page 75: Table 12 Volume Of Water Per Cleaning

    A175-L A180-L A185-L A190-L 81125 G1/2" G1/2" G1/2" G1/2" G1/2" G1/2" 45 Nm 45 Nm 45 Nm 45 Nm 45 Nm 45 Nm Table 13: Tightening torques (81125) © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 76: Cleaning The Turbine During Operation

    The dry cleaning of the turbine end components is carried out at an engine load of 5 … 85%. Cleaning several turbochargers If several turbochargers are installed on an engine, ABB Turbo Systems recommends clean- ing one turbine after the other. © Copyright 2016 ABB. All rights reserved.
  • Page 77 Cleaning instruction (51717) On-Off valve [closed] (51705) Gas inlet casing, insulated Protecting the pressurised air system Protect the pressurised air system against overpressure (> 10 bar).  CAUTION © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 78 Repeating the cleaning If the cleaning is still unsuccessful after three processes, it is recommended to have the turbo- charger checked and cleaned by an ABB Turbocharging Service Station if the engine values are unsatisfactory. Optimum cleaning effect It is important that the specified amount of granulate is blown in for each cleaning process in order to achieve an optimum cleaning effect.

  • Page 79: Table 14 Amount Of Granulate

    Table 14: Amount of granulate Storage of dry cleaning materials The cleaning material must be stored in a dry and clean location to prevent blockage of the pipes when cleaning. NOTICE © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 80: Draining The Gas Outlet Casing

    Set the drain cock (02) to position 2 (B) and clean the drain pipe (01) with air from the  compressor casing (04). If cleaning with air is not sufficient, the drain pipe (01) must be cleaned mechanically. © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 81: Troubleshooting

    To prevent significant loss of effi- ciency, specific tolerances must be fulfilled.  If there is any doubt about the extent of the rubbing, contact an ABB Turbocharging Service Station.  Have a dimension check carried out by an ABB Turbocharging Service Station.

  • Page 82: Malfunctions During Operation

    Contact ABB Turbocharging Service Station Pipes Defects, such as leaks, in the exhaust Repair gas pipes or charge air ducts Table 19: Malfunctions during operation – Speed reductions © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 83: Table 21 Malfunctions During Operation - Charge Air Pressure Too Low

    Clean or repair boiler or exhaust gas si- lencer Pipes Pipes downstream to the compressor out- Repair. let not sealed. Table 21: Malfunctions during operation – Charge air pressure too low © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 84: Surging Of The Turbocharger

    If the turbocharger surges continuously or periodically, parts of it can be damaged. CAUTION Slowly reduce the engine load.  Have the cause clarified immediately by an ABB Turbocharging service  station and rectified. Have components inspected for damage and, if necessary, replaced by ...

  • Page 85: Malfunctions When Stopping

    Turbocharger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Table 25: Malfunctions when stopping - run-down time shortened © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 86: Speed Measurement System

    If none of the above measures eliminates the malfunction, we rec- sources of ommend that you have the speed measuring system inspected by errors an ABB Turbocharging Service Station. Table 26: Malfunctions of the speed measurement system © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 87: Disassembly And Assembly

    ABB Turbo Systems recommends having further operations carried out  only by trained personnel from an ABB Turbocharging Service Station. Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to dis- assembly. NOTICE Identification of the assembly devices Not all assembly devices are marked with a part number.
  • Page 88 Disassembly and assembly Page 58 / 111 Tightening torques for assembly devices Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB Turbo Systems must be tightened so they rest firmly against the surface. Suspended loads Loads that are not attached according to regulations can cause injury to per- sonnel or fatal accidents.

  • Page 89: Weights Of Assemblies

    The total weight of the complete wall insert is made up of the wall insert and diffuser assem- blies. A165-L A170-L A175-L A180-L A185-L A190-L 1290 1770 Table 28: Weight of wall insert [kg] © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 90: Disassembly And Assembly Of The Filter Silencer Casing

    01, 02 Bottom part 03, 04, 07, 08 Side part 05, 06, 09 Circumferential part 10, 11 Flange The complete filter silencer casing has the part number 81500. © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 91 NOTICE Before disassembling the bottom part (01), mark the location of screw (A).  Fit all remaining screws on the bottom part (01).  © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 92 Fit the side parts (03) and (04) with the screws on the filter silencer and on the bottom part.  Fit the side parts (07) and (08) with the screws on the filter silencer, on the bottom part,  and on the side parts (03, 04). © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 93 Figure 27: Fitting filter silencer casing 5 Fit the circumferential part (05) with the screws.  Fit the circumferential part (06) with the screws.  Fit the circumferential part (09) with the screws.  © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 94: Table 29 Tightening Torques

    Tighten all screws of the circumferential parts (05, 06, 09).  Bellows Figure 28: Fitting the bellows Fit bellows (C) with frame (F), screws (S) and nuts (N) on the filter silencer casing.  © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 95: Dismantling The Filter Silencer

    1. Attach the lifting gear to the front lug and rear eyelet of the filter silencer (81000). 2. Loosen nuts (72004) and remove with washers (72003). 3. Remove and put down filter silencer. © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F...

  • Page 96: Dismantling The Filter Silencer With Noise Package

    3. Loosen nuts (72004) and remove with washers (72003) and insulating discs (81302). 4. Remove and put down filter silencer. 5. Remove the gasket (81301). 6. Loosen counter-sunk screws (74043), remove with air outlet silencer (74040) and gasket (74042). © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 97: Dismantling Wall Insert And Diffuser

    5. Fit lifting device (90190) with crane on upper area of wall insert (77000). 6. Change the position of the shackle with the lifting gear to P2 of the lifting device (90190). © Copyright 2016 ABB. All rights reserved. HZTL4034_EN...
  • Page 98 Figure 33: Putting down wall insert Put down wall insert (77000) with diffuser (79000) in horizontal position and use appropri-  ate supports to prevent it from falling over and rolling away. © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 99 1. Put wall insert (77000) down on suitable supports. 2. Tilt wall insert (77000) with diffuser (79000) against lifting device (90190). 3. Place wall insert with the flange (F) on the underlay. © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F...
  • Page 100 Figure 35: Dismantling the diffuser 4. Loosen and remove screws (77015). 5. Remove O-rings (79020, 79021). 6. Attach lifting gear (L) to the diffuser (79000). 7. Remove and put down diffuser. © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 101: Axial Clearance A Prior To Disassembly

    Serious damage to engines or property can be caused by clearances out- side the tolerance and excessively worn parts. CAUTION Have the components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. © Copyright 2016 ABB. All rights reserved.

  • Page 102: Dismantling Insulation, Gas Inlet Casing And Nozzle Ring (A175-L And Smaller)

    1. Loosen and remove screws of insulation jackets (51200) from gas outlet casing (61001). 2. Loosen and remove all connecting plates of insulation jackets. 3. Remove insulation jackets. 4. Detach flange connection between gas inlet casing (51001) and bellows. © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 103 Dismantling the nozzle ring Figure 39: Dismantling the nozzle ring (A175-L and smaller) 1. Loosen screws (56014) and remove with washers (56011). 2. Remove and put down nozzle ring (56001). © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 104: Dismantling The Gas Inlet Casing, Nozzle Ring (A180-L And Larger)

    6. Loosen remaining screws and carefully move out gas inlet casing. 7. Fit support (90451) on gas inlet casing and put down casing. 8. Remove the guide studs. © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 105 Figure 41: Fitting the nozzle ring holder 1. Remove screws (B 2. Fit the nozzle ring holder (90477) with screws (B ) at the top of the flange of the gas inlet casing (51001). © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 106 ) into the nozzle ring holder. 5. Remove screws (B Figure 43: Putting down the nozzle ring (A180-L and larger) Use the crane to remove and put down the nozzle ring (56001).  © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 107: Fitting Gas Inlet Casing, Nozzle Ring And Insulation (A175-L And Smaller)

    ) with the flange connection (A ) and slide the nozzle ring (56001) into the gas inlet casing (51001). 2. Fit screws (56014) with high-temperature grease and with washers (56011). © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 108: Table 32 Tightening Torque (61009)

    6. Fit the screws (61009) by tightening them crosswise, first to the pre-tightening torque, then to the tightening torque. 7. Remove the lifting gear. 8. Connect the flange of the gas inlet casing and the bellows. © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 109 2. Fit the insulation jackets (51200) on the gas inlet casing (51001) with the screws. 3. Fit connecting plates of insulation jackets with screws. 4. Fit insulation jackets with screws on gas outlet casing (61001). © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F...

  • Page 110: Fitting The Gas Inlet Casing, Nozzle Ring (A180-L And Larger)

    Figure 47: Looping around the nozzle ring (A180-L and larger) Loop around the nozzle ring (56001) with lifting gear on the nozzle ring holder (90477) and  fix on the crane. © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 111: Table 33 Tightening Torque (56014)

    4. Coat screws (56014) with high-temperature grease and fit with washers (56011). 5. Remove screws (B ) along with the nozzle ring holder (90477). © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 112: Table 34 Tightening Torque (61009)

    8. Remove the lifting gear. 9. Connect the flanges of the gas inlet casing and the bellows. 10. Fit the insulation segments (51215). © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 113: Axial Clearance A After Assembly

    Serious damage to engines or property can be caused by clearances out- side the tolerance and excessively worn parts. CAUTION Have the components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. © Copyright 2016 ABB. All rights reserved.

  • Page 114: Fitting Diffuser, Wall Insert

    3. Fit new O-rings (79020, 79021) on the diffuser. 4. Degrease screws (77015) and threaded holes in wall insert. 5. Coat threads of the screws with Loctite® 542. 6. Fit screws. © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 115 Disassembly and assembly Page 85 / 111 Fitting the wall insert Figure 52: Positioning wall insert Carefully bring wall insert (77000) into vertical position with the lifting device (90190).  © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 116: Table 37 Tightening Torque (72011)

    7. Completely insert the wall insert and then remove the guide studs (90320). Check that both casings are in the correct position (the marking arrows are aligned to one another). 8. Fit screws (72011). © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 117: Fitting The Filter Silencer

    1. Attach the lifting gear to the front lug and rear eyelet of the filter silencer (81000). 2. Position filter silencer on compressor casing. 3. Fit nuts (72004) with washers (72003) and tighten. Fit insulation as far as necessary.  © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 118: Fitting The Filter Silencer With Noise Package

    72004 130 Nm 200 Nm 300 Nm 420 Nm 570 Nm 710 Nm 74043 45 Nm 45Nm 45Nm 45Nm 45Nm 45 Nm Table 39: Tightening torques (72004, 74043) © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 119 4. Fit nuts (72004) with washers (72003) and insulating discs (81302) and tighten. 5. Fit insulation ring (81300). 6. Fit air outlet silencer (74040) with gasket (74042) and secure with counter-sunk screws (74043). Fit insulation as far as necessary.  © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 120: Table Of Tightening Torques

    Operation Manual / 4 Product description / A100-L Disassembly and assembly Page 90 / 111 8.16 Table of tightening torques Figure 56: Overview of tightening torques Figure 57: Overview of speed sensor tightening torque © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 121: Table 13 Tightening Torques

    2) Pre-tightening torque of the screws Use hydraulic tool for tightening torques exceeding 500 Nm.  compressor casing insulation 25 Nm 45 Nm 85 Nm 50 Nm Table 41: Tightening torque, insulation © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 122 Operation Manual / 4 Product description / A100-L Disassembly and assembly Page 92 / 111 © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 123: Taking A Turbocharger Out Of Operation

    Sound an alarm and depending on the situation, stop the engine.  Seal oil leaks.  Soak up oil and dispose of in an environmentally compatible manner.  Wear safety gloves to protect against thermal hazards. © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 124: Procedure With One Installed Turbocharger

    CAUTION unscrewed on the compressor wheel. Before recommissioning of the turbocharger, the compressor wheel must be balanced at an ABB Turbocharging Service Station. Do not screw any set screws that have become unscrewed into the com-  pressor wheel again.
  • Page 125 Close the lubricating oil supply to the turbocharger.  Open the bypass around the turbocharger.  Observe specifications from enginebuilder.  © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 126: Table 44 Required Washers (01)

    If the nozzle ring is removed for emergency operation, the clamping of the cover ring (57001) to the gas outlet casing must be ensured. In this case, additional washers (01) must be pro- vided in accordance with the following table. These washers (01) are not included in the ABB Turbo Systems scope of delivery.
  • Page 127 Page 97 / 111 9.3.4 Continuing to operate the engine Continue to operate engine in accordance with enginebuilder's instructions. Do not exceed prescribed power reduction and maximum turbocharger speed. © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 128: Procedure With Two Or More Installed Turbochargers

    Observe specifications from enginebuilder.  9.4.2 Continuing to operate the engine Continue to operate engine in accordance with enginebuilder's instructions. Do not exceed prescribed power reduction and maximum turbocharger speed. © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 129: Mothballing The Turbocharger

    If the total acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking an engine out of operation: Dismantle the turbocharger.  The rotor and the bearing parts must be removed by an official ABB Turbocharging service  station and refitted afterwards. Clean all parts.

  • Page 130: 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 has been completely removed, either as a whole unit or in individual...

  • Page 131: Disposing Of Turbocharger Components

    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 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 133: Spare Parts

     Serial number (HT……)  Designation and part number. Spare parts can be ordered from any ABB Turbocharging Service Station. If different model variants are not taken into account in this document, contact an ABB  Turbocharging Service Station. Required customer spare part set (97070) For the operations described in the Operation Manual, the customer spare part set (97070) is required.
  • Page 134 Operation Manual / 4 Product description / A100-L Spare parts Page 104 / 111 12.2 View of turbocharger with part numbers Figure 60: View of turbocharger with part numbers © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 135: Table 47 Turbocharger With Part Num

    81000 Filter silencer 81300* Insulation ring (option) 81301* Gasket (option) 81302* Insulating disc (option) Table 47: Turbocharger with part numbers * Depending on the specification of the turbocharger © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 136 Figure 61: View of cartridge group with part numbers Cartridge group The cartridge group is not delivered as a fitted assembly. Spare parts must be ordered individually. NOTICE © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

  • Page 137: Table 48 Cartridge Group With Part

    42306 O-ring 42307 O-ring 42320 Socket screw 42458 Blind flange 86505 Speed sensor 86506 (in the customer spare part set) O-ring Table 48: Cartridge group with part numbers © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 139 Fig. 29 Dismantling the filter silencer ..Fig. 57 Overview of speed sensor tight- ening torque ......90 Fig. 30 Dismantling the filter silencer with noise package ....© Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 140 Fig. 59 Ensuring clamping of the cover ring ..........96 Fig. 60 View of turbocharger with part numbers ........104 Fig. 61 View of cartridge group with part numbers ......106 © Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...
  • Page 141 Table 21 Malfunctions during operation – Charge air pressure too low . Table 22 Malfunctions during operation – Charge air pressure too high Table 23 Surging of the turbocharger ..© Copyright 2016 ABB. All rights reserved. HZTL4034_EN Revision F June 2016...

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