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Operation Manual / A200-L

Table of contents

HZTL4036_EN

Rev.T

December 2021

Operation Manual / A200-L

Introduction............................................................................................................ 4

1.1

Essential information.................................................................................................... 5

1.2

Registered trademarks ................................................................................................. 5

1.3

Layout and function of the turbocharger ................................................................ 6

1.4

Locations of the rating plates.................................................................................... 8

Safety ...................................................................................................................... 9

2.1

Introduction ................................................................................................................... 9

2.2

CE conformity ................................................................................................................ 9

2.3

Definition of mandatory signs .................................................................................. 10

2.4

Definition of safety instructions .............................................................................. 10

2.5

Intended use ................................................................................................................. 11

2.6

Deflagration on gas engines ..................................................................................... 12

2.7

Warning plates on the turbocharger........................................................................ 13

2.8

Turbocharger rating plate.......................................................................................... 13

2.9

Periodic check of the pressure vessels.................................................................... 15

2.10

Lifting of loads ............................................................................................................. 16

2.11

Prerequisites for operation and maintenance....................................................... 17

2.12

Hazards during operation and maintenance ......................................................... 18

2.13

Safe operation ............................................................................................................. 20

2.14

Safe maintenance ....................................................................................................... 20

Removal and installation .................................................................................... 26

3.1

Turbocharger weight ................................................................................................. 26

3.2

Removing the turbocharger...................................................................................... 26

3.3

Installing the turbocharger ...................................................................................... 28

Commissioning .................................................................................................... 31

4.1

Oil supply ....................................................................................................................... 31

4.2

Inspection procedures ................................................................................................ 31

4.3

Commissioning after taking out of operation...................................................... 33

Monitoring during operation.............................................................................. 34

5.1

Oil pressure, oil temperature.................................................................................... 34

5.2

Admissible air inlet temperature .............................................................................. 37

5.3

Turbocharger speed .................................................................................................... 37

5.4

Low pressure measurement at the filter silencer ................................................ 40

Operation and service ......................................................................................... 41

6.1

Noise emission ............................................................................................................. 41

6.2

Service work ................................................................................................................. 42

6.3

Expected replacement intervals .............................................................................. 46

6.4

Flexible turbocharger cut-out .................................................................................. 47

Summary of Contents for A100-L Series

Page 1: ... the pressure vessels 15 2 10 Lifting of loads 16 2 11 Prerequisites for operation and maintenance 17 2 12 Hazards during operation and maintenance 18 2 13 Safe operation 20 2 14 Safe maintenance 20 3 Removal and installation 26 3 1 Turbocharger weight 26 3 2 Removing the turbocharger 26 3 3 Installing the turbocharger 28 4 Commissioning 31 4 1 Oil supply 31 4 2 Inspection procedures 31 4 3 Commis...

Page 2: ...er silencer 78 9 6 Dismantling wall insert and diffuser 80 9 7 Axial clearance A prior to disassembly 86 9 8 Dismantling the insulation A275 L 87 9 9 Dismantling the gas inlet casing A275 L 88 9 10 Dismantling the nozzle ring A275 L 89 9 11 Dismantling the gas inlet casing A280 L 90 9 12 Dismantling the nozzle ring A280 L 91 9 13 Fitting the nozzle ring A275 L 93 9 14 Fitting the gas inlet casing ...

Page 3: ...ZTL4036_EN Rev T December 2021 12 Material and Disposal 118 12 1 REACH and RoHS Compliance Declaration For Products 118 12 2 Disposing of turbocharger components 119 13 Spare parts 120 13 1 Ordering spare parts 120 13 2 Spare Part Illustrations 122 14 Tools 140 Figures 142 Tables 144 ...

Page 5: ...re 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 Accuracy of illustrations The illustrations in this document are general in nature and intended for ease of understand ing Differences in detail are therefore possible 1 2 Registered tradema...

Page 6: ...3 Layout and function of the turbocharger Fig 1 Layout and function of the turbocharger 01 Filter silencer 08 Gas inlet casing 02 Thrust bearing 09 Bearing casing 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 Page 6 145 ...

Page 7: ...through the filter silencer 01 to the compressor wheel 11 The air then flows through the diffuser 10 and exits the turbocharger through the compressor cas ing 12 An air outlet silencer 13 is optionally available If installed this will reduce the amount of noise generated by the components at the outlet side after the compressor cas ing The rotor runs in two radial plain bearings 03 04 which are lo...

Page 8: ...g plates Copyright 2021 ABB All rights reserved HZTL4036_EN Rev T December 2021 1 4 Locations of the rating plates Fig 2 Locations of the rating plates One rating plate 01 each is attached on the left and the right side of the turbocharger bear ing casing Page 8 145 ...

Page 9: ...cient compliance with safety instructions are a consequence of insufficient or inappropriate performance of maintenance and in spection work The operating company is responsible for defining measures that regulate safe access to and safe handling of the turbocharger All instructions contained in this chapter must be observed for safe and trouble free opera tion of the turbocharger and during all w...

Page 10: ...ry mask to protect against Dusts Gases Safety helmet Ear protection Table 2 Personal protective equipment to be worn specific to the respective task 2 4 Definition of safety instructions WARNING Definition of Warning Non compliance or inaccurate compliance with working or operating in structions indicated by this symbol and the word WARNING can lead to seri ous injuries to personnel and even to fa...

Page 11: ...recirculation EGR it must be ensured that these are cleaned as well as possible and that no water droplets or exhaust gas particles enter the compressor inlet The specific operating limits of the turbocharger were determined on the basis of informa tion from the enginebuilder about the intended use These data are given on the rating plate The use of the turbocharger is limited to the specific appl...

Page 12: ...ur bocharger or improper operation 2 6 Deflagration on gas engines ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar After a deflagration event ABB recommends verifying the following points on the turbochar ger Position of the turbine and compressor casings to the bearing casing Shifting of the bearing casing in relation to the bracket Cracks in casings If ...

Page 13: ...locations or not readable proceed as fol lows u Order new warning plates from ABB Turbocharging Service Stations u Remove any warning plates that have become unreadable u Clean and degrease the areas designated for the warning plates u Fit new warning plates and remove protective sheets Turbochargers supplied to the enginebuilder without insulation must be equipped later with warning plates on the...

Page 14: ...ilder 02 Turbocharger operating limits during operation Recommended replacement intervals of turbocharger components 03 Replacement interval of plain bearings in 1000 h 04 Replacement interval of compressor in 1000 h 05 Replacement interval of turbine in 1000 h Further data 06 Customer part number 07 Designation for special design 08 Weight of turbocharger in kg 09 Turbocharger type 10 Serial numb...

Page 15: ...bove nMmax and tMmax is not permitted Non observance of the recommended replacement intervals increases the risk of unpredict able component failures Locations of the rating plates The locations of the rating plates are defined in the Operation Manual 2 9 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...

Page 16: ... mechanical hazards Wear safety helmet Fig 5 Attachment of loads on the crane hook Fig 6 Attachment angle If there are two or more suspension points the attachment angle of 45 must not be ex ceeded This prevents excessive loading due to diagonal pull u Before looping around the components of the turbocharger let them cool down max imum 80 C u Attach components of the turbocharger as described in t...

Page 17: ...tion Manual must be checked periodically Suitable working materials and personal protective equipment must be kept in a perfect condition Only authorised personnel may remain in the vicinity of the turbocharger when the engine is running Competence of personnel The turbocharger must only be operated and serviced by trained and authorised personnel Basic mechanical training is a prerequisite Modifi...

Page 18: ...r ear protection u Always wear ear protection if the sound pressure level exceeds 85 dB A Wear ear protection Hazards due to hot surfaces Surfaces of the turbocharger attached parts and operating fluids lubricating oil get hot during operation The surface temperature depends on the efficacy of the existing insula tion The temperature may rise to a level that can cause burns WARNING Danger of burns...

Page 19: ...ontact with hot surfaces u Compliance with the instructions and specifications given by the en ginebuilder to protect against hot turbocharger surfaces is compulsory Wear safety gloves to protect against thermal hazards Hazards due to rotating parts WARNING Hazards due to rotating parts Contact with rotating parts can cause severe injury The turbocharger is never allowed to be operated without fil...

Page 20: ...ediately and safeguard against accidental unauthorised use u 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 2 14 Safe maintenance Occupational safety WARNING Injuries to persons Severe injuries to personnel or fatal accidents can be caused by mechanical influences as a consequence of haz...

Page 21: ...e of assembly devices Assembly devices are specially constructed and designed for the defined use they are not commercially available products u Use assembly devices only for the described applications Welding work in the vicinity of the turbocharger u When performing welding work in the vicinity of the turbocharger always cover the filter silencer to prevent the filter mat from being damaged u Ke...

Page 22: ...r u Before taking off any cover or removing any guard from the turbocharger switch off the engine and wait until the turbocharger has come to a standstill u Make sure that the oil supply is interrupted especially with an external oil supply u Only restart the engine after all parts have been properly fitted again and oil supply is en sured CAUTION Mechanical operations on the turbocharger Componen...

Page 23: ...s for which you have previously received instruc tion or training Hazards due to operating materials and supplies Operating materials and supplies are substances required for the operation of the tur bocharger or for the performance of maintenance work Oils greases coolants detergents and solvents acids and similar substances can be classified as hazardous substances WARNING Handling operating mat...

Page 24: ... material safety data sheet for the operat ing materials and supplies u Comply with local legislation Hazards due to the handling of insulation materials WARNING Danger from insulation materials Dust or fibres from insulation materials can have adverse effects on the health or cause irritations Unsuitable and combustible insulation materials are a fire hazard u Only use suitable and non combustibl...

Page 26: ...ecified here Product Weight of complete turbocharger unit kg A255 L 1350 A260 L 1550 A265 L 2600 A270 L 3800 A275 L 6300 A280 L 8700 Table 3 Total weight 3 2 Removing the turbocharger WARNING Risk of tipping If the turbocharger is not sufficiently supported or not supported at all dur ing removal and installation it may tip over and cause severe injury to per sonnel or accidents resulting in fatal...

Page 27: ...charger Copyright 2021 ABB All rights reserved HZTL4036_EN Rev T December 2021 Fig 7 Fitting the lifting gear u Loosen fixing screws on compressor end and turbine end foot u Lift turbocharger from engine and put down in a suitable location u Cover oil connections Page 27 145 ...

Page 28: ...on the bracket Fig 8 Placing the turbocharger u Remove covers from the oil connections u Align turbocharger and place on engine bracket u Tighten the fixing screws Steps for fastening the turbocharger while only slightly loosening the lifting gear u Remove lifting gear from turbocharger u Connect cable to speed sensor u Connect all gas air and oil pipes See also 2 Steps for fastening the turbochar...

Page 29: ...or end a height of turbocharger foot a Dimension a turbine end a height of turbocharger foot F spacer sleeve D Dimension b Hole in bracket Dimension c Thread length 1 5 x nominal thread diameter Coefficient of friction 0 12 lightly oiled Table 4 General information about fastening the turbocharger Compressor end foot Fig 9 Compressor end foot u Tighten the foot fixing screws or nuts diagonally acc...

Page 30: ...e 5 Tightening torques foot screws Angle controlled tightening Product Thread size Height a foot mm Pre tightening torque Nm Tightening angle height a DEG Additional tightening angle for every 10 mm of ad ditional screw length b DEG A255 L M27 60 220 30 3 1 A260 L M27 60 220 30 3 1 A265 L M22 86 120 30 3 7 A270 L M27 100 220 30 3 1 A275 L M30 120 300 30 2 6 A280 L M33 136 400 35 2 6 Table 6 Tighte...

Page 31: ...ter mesh width of 0 050 mm is sufficient for the tur bocharger 4 1 3 Oil pressure Comply precisely with the oil pressure before the turbocharger for trouble free operation If the oil pressure at the inlet of the turbocharger is too high it can be reduced with a throttle valve The throttle valve is normally already fitted on the turbocharger and has been correctly set by the enginebuilder This take...

Page 32: ...m oil u Use special running in filters when running in the engine and after all ser vice work on the lubricating system u Check that the oil filter is clean before commissioning u Check the oil pressure in the oil supply pipes Warning plates u Check whether warning plates are present and legible u Check whether the protective sheets have been removed from new warning plates 4 2 3 Checks after comm...

Page 33: ... liquefy or vaporise and escape as oily fluids during the initial hours of operation Continual escape of an oily fluid indicates an oil leak u If there is a leak contact an ABB Turbocharging Service Station 4 3 Commissioning after taking out of operation If present u Remove cover plates blind flanges from the compressor casing the gas inlet and the gas outlet General u Check the exhaust gas pipe b...

Page 34: ...n oil temperature range at the inlet of 30 65 C with an oil temperature range at the inlet of 65 80 C 0 8 4 0 1 0 4 0 Temporarily admissible 1 h alarm with an oil temperature range at the inlet of 30 65 C with an oil temperature range at the inlet of 65 85 C 0 6 0 8 0 8 1 0 Not admissible emergency stop with an oil temperature range at the inlet of 30 65 C with an oil temperature range at the inle...

Page 35: ...at the outlet is listed in the following table The specified oil outlet temperature is to be considered as alarm value for the turbocharger op eration and must be monitored according to the current regulations Fig 11 Oil temperature at the outlet Status for operation Oil temperature at the inlet Toil inlet C Oil temperature at the outlet Toil outlet C Admissible 45 110 Admissible 80 125 Temporaril...

Page 36: ... damage to engine or property can result if the turbocharger is not supplied with oil from the first moment after starting the engine u Activate the pre lubrication device each time before starting the engine The pre lubrication time is at least 5 minutes The post lubrication time is at least 10 minutes If the engine is operated for 5 to 10 minutes in idle mode before stopping no additional post l...

Page 37: ...urbocharger must be permanently monitored CAUTION Do not use cables as a climbing aid If you pull the speed measurement cables too hard contacts can be pulled out u Do not tension the speed measurement cables 5 3 2 Layout and overview Fig 12 Layout and overview of the speed measurement system 86505 Speed sensor 86528 Tachometer 86506 O ring 42047 Screw plug 86515 Cable connector 32109 Sealing disc...

Page 38: ...the maximum tur bocharger speed does not exceed 70 of nBmax u If the engine cannot be stopped it can continue to be driven at this reduced engine load or turbocharger speed u If a turbocharger surges continuously the engine performance must be reduced further u Measure the temperatures in the air lines and gas piping from and to the turbochargers and compare with normal values If clear deviations ...

Page 39: ...ling lip and does not require a sealing disc for as sembly Fig 13 Replacing the speed sensor Part number A255 L A260 L A265 L A270 L A275 L A280 L 86505 M18x1 5 150 Nm M18x1 5 150 Nm M18x1 5 150 Nm M18x1 5 150 Nm M18x1 5 150 Nm M27x2 320 Nm Table 10 Tightening torques 86505 u Reduce the engine performance to idling and then stop the engine Pay attention to post lubrication Stopping the engine 48 u...

Page 40: ...cal culation of the turbocharger efficiency When using a filter mat An increased pressure loss indicates an increase in the fouling of the filter material 5 4 2 U tube manometer at the filter silencer Fig 14 U tube manometer at the filter silencer 81000 Filter silencer 81050 U tube manometer A mm H2O Pressure loss pressure difference If the turbocharger is operated at maximum engine power and pres...

Page 41: ...1 meter from the turbocharger The highest value of the emission sound pressure level1 reaches a maximum of 105 dB A near the air inlet The following prerequisites must be fulfilled with regard to the turbochar ger to observe this limit value Air inlet system has been fitted All standard noise reducing measures2 have been fitted Bellows at the air outlet has been acoustically insulated by the engin...

Page 42: ...ork enables the detection and rectification of changes to the tur bocharger and ensures full operability of the turbocharger CAUTION Service intervals Any service work on the turbocharger that is omitted or performed too late can cause excessive contamination wear and operating failures u Carry out the service work at the specified time intervals CAUTION Specific service interval Exceptional stres...

Page 43: ...ning u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en gine is stopped in accordance with the instructions of the enginebuilder 6 2 3 Service work on turbocharger every 18000 hours It is recommended to have this service work and these checks carried out by an ABB Tur bocharging Service Station Damaged and worn out parts must be replaced with original ABB...

Page 44: ...u Remove the filter silencer u Clean filter silencer and check for damage u Dismantle the wall insert u Check axial clearance A u Clean wall insert diffuser and compressor casing and check for damage u Remove the gas inlet casing and dismantle the nozzle ring and cover ring u Clean the nozzle ring and cover ring and check for damage u Dismantle inspect and balance the rotor u Replace the plain bea...

Page 45: ...ng data and measured values must be entered regularly into the engine logbook of the enginebuilder Performance and speed of the engine Speed of the turbocharger Air intake temperature Exhaust gas temperature before and after the turbine Pressure of the charge air Pressure loss in the charge air cooler Lubricating oil pressure and lubricating oil temperature Pressure loss in the filter silencer Air...

Page 46: ...asing 50000 100000 Gas outlet casing 50000 100000 Nozzle ring 35000 50000 Cover ring 25000 50000 Other casings 100000 Table 11 Expected replacement intervals for turbocharger parts HFO Heavy Fuel Oil Recommended replacement intervals h Rotor components See information on rating plate Bearings See information on rating plate Table 12 Recommended replacement intervals for turbocharger parts The spec...

Page 47: ...an result in inadmissible turbocharger speeds which can lead to serious damage to property with grave consequences u The air outlet flap and gas inlet flap must be completely open during nor mal operation u During cut out operation the air outlet flap and gas inlet flap must be completely closed CAUTION Manual switching of the flaps If the gas inlet flap is opened during cut out operation or the a...

Page 48: ...ice 6 5 Stopping the engine Copyright 2021 ABB All rights reserved HZTL4036_EN Rev T December 2021 6 5 Stopping the engine u Observe the instructions regarding post lubrication Pre lubrication and post lubrication 36 u Stop the engine Page 48 145 ...

Page 49: ...36_EN Rev T December 2021 7 Periodic maintenance 7 1 Foreword to maintenance Maintenance work includes regular visual controls and cleaning operations which are inten ded to ensure the trouble free functioning of the turbocharger Described maintenance points Filter silencer Compressor Turbine and nozzle ring Page 49 145 ...

Page 50: ...silencer Filter silencer with tension band Fig 16 Layout and overview of filter silencer 81126 Lock 81266 Cover grid 81135 Body of filter silencer 81268 Connecting strip 81136 Absorption segment 81270 Tension band 81137 Sheet metal covering 81271 Lock 81265 Filter ring if present 81400 Water connection E Insert unit absorption segment sheet metal covering fitted Page 50 145 ...

Page 51: ... strips 81268 see Fig 16 Layout and overview of fil ter silencer 50 u Pull out insert units E u Bend up the sheet metal coverings 81137 and remove the absorption segments 81136 u Clean the absorption segments 81136 When cleaning note that the absorption segments may only be cleaned lightly with pres surized air with a soft brush or a moist cleaning cloth Otherwise there is a danger of damage or ch...

Page 52: ...2021 7 3 Changing the filter strip on the filter silencer casing This chapter applies only to turbochargers with filter silencer casing The filter ring 81265 is replaced with the filter silencer installed Fig 17 Dismantling filter ring circumferential part u Dismantle circumferential part 9 Fig 18 Opening filter ring lock u Open the lock of the filter ring 81265 Page 52 145 ...

Page 53: ...ing new filter ring u Attach the new filter ring 81265 on the filter ring to be replaced so they overlap Fig 20 Fitting new filter ring u Pull on the old filter ring until the new filter ring is completely wrapped around the filter silencer u Undo the connection between the new and the old filter ring u Fasten the newly installed filter ring 81265 then fit circumferential part 9 Page 53 145 ...

Page 54: ...otor unbalance Periodic cleaning of the compressor during operation prevents or delays any major increase in contamination But it never replaces the regular service work where the turbocharger is completely dismantled and the compressor is mechanically cleaned Cleaning interval The interval between the cleaning cycles depends greatly on the operating conditions Cleaning should normally be carried ...

Page 55: ... and adversely affect turbocharger parts u Never use salt water but only pure water for cleaning To clean the compressor stage during operation water is injected upstream of the com pressor wheel The water does not act as a solvent The coating is removed by the mechanical action of the impacting droplets The procedure is perfectly suitable provided that the contamination has not progressed too far...

Page 56: ...ways wear ear protection when carrying out wet cleaning on the com pressor Wear ear protection Fig 21 Overview of wet cleaning of compressor 81000 Filter silencer A Can 81126 Lock B Filler opening u Remove insulation from flange of filter silencer 81000 if present u Unscrew lock 81126 u Measure volume of water according to the following table u Pour this water into a clean can A u Carefully pour t...

Page 57: ...A280 L 3 0 Table 13 Volume of water per cleaning process The filling time is 4 15 seconds Checking the filter plug The filter plug only needs to be checked in the turbocharger version with a cast filter silen cer See chapter Design variants 78 Fig 22 Filter plug view Disassembly and checking of the filter plug 81125 is required if 20 seconds after the clean ing process water is still visible in fi...

Page 58: ...turbine and the nozzle ring are cleaned during operation using the dry cleaning method This cleaning method is tested and approved by ABB Turbocharging Interval for dry cleaning depending on the fuel used The interval between the cleaning cycles depends greatly on the operating conditions and fuel used General recommendation every 50 hours according to the cleaning instructions for the dry cleanin...

Page 59: ... device Fig 23 Dry cleaning device 11 Granulate container 51702 16 Protection valve closed 51713 12 Cover cap 51703 17 Pressurised air valve venting 51704 13 Pressurised air supply 4 7 bar 18 Plate 14 Piping 19 Cleaning instructions 51717 15 On Off valve closed 51705 20 Gas inlet casing insulated CAUTION Protecting the pressurised air system u Protect the pressurised air system against overpressur...

Page 60: ...cap 12 u Fill the specified amount of granulate into the container 11 u Screw on and tighten the cover cap 12 u Open the combined pressurised air valve pressure release valve 17 down lever posi tion u Open the protection valve 16 u Open the on off valve 15 for cleaning the turbine for 3 4 minutes u Close the on off valve 15 u Close the protection valve 16 u Set the combined pressurised air valve p...

Page 61: ...ulated materials such as natural core granulates Soft blast media Activated carbon particles The average grain size of the cleaning granulate must be between 1 2 and 2 0 mm The specific weight of the cleaning granulate must not exceed 1 2 kg dm3 Amount of granulate per turbocharger Product Quantity dm3 A255 L 0 6 A260 L 0 6 A265 L 1 0 A270 L 1 5 A275 L 2 0 A280 L 2 5 Table 15 Cleaning parameters N...

Page 62: ...other causes the gas outlet casing can be drained Fig 24 Drain pipe diagram 01 Drain pipe A Position 1 02 Drain cock B Position 2 03 Drain 04 Air line from compressor casing u On the drain pipe 01 set the drain cock 02 to position 1 A If the drain pipe 01 is blocked u 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 no...

Page 63: ... Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Contact enginebuilder Table 17 Malfunctions when starting Vibrations Rubbing of rotating parts Normal behaviour not a malfunction Turbochar ger A slight amount of uniform wear at the circumference of the rotor components caused by slight local rubbing against adjacent components is permitted This causes the compressor or ...

Page 64: ...nmentally compatible manner Wear safety gloves to protect against thermal hazards Possible causes Remedy Turbochar ger Axial clearance of the rotor excessive Contact an ABB Turbocharging Service Station Engine Oil filter heavily contaminated Clean Oil pump in lubricating system defect ive Check replace Manometer displays incorrectly Replace manometer Table 19 Malfunctions during operation Lubricat...

Page 65: ...clean cooling system Insufficient ventilation Improve ventilation Table 21 Malfunctions during operation Exhaust gas temperature too high Charge air pressure too low Engine performance and engine speed unchanged suction condition normal Possible causes Remedy Turbochar ger Manometer display not correct Replace manometer Supply pipe to manometer not sealed Repair leak Filter silencer contaminated t...

Page 66: ...f the turbocharger Surging of the turbocharger Possible causes Remedy Turbocharger Filter silencer or diffuser contamin ated Clean Periodic maintenance 49 Heavy dirt deposits in the turbine or in the nozzle ring Engine Protective grating in front of the tur bocharger contaminated or damaged Clean replace Charge air cooler Cooler contaminated Clean Charge air duct blocked Table 24 Surging of the tu...

Page 67: ...turbocharger A surge blow is accompanied by a loud bang and escape of hot air from the filter silencer 8 4 Malfunctions when stopping Runout noises Possible causes Remedy Turbochar ger Turbocharger contaminated Clean Bearing damaged Contact an ABB Turbocharging Service Station Rotor rubbing Foreign object in the turbocharger Table 25 Malfunctions when stopping Runout noises Shortened runout time P...

Page 68: ...ics This problem will be remedied by removing the gasket Sensor defective Contact ABB Turbocharging Service Station Measured speed too high Contamination of the sensor tip As the sensor tip is magnetic it can attract material particles This reduces the distance to the auxiliary bearing which can lead to amplification of the noise component and therefore to false triggering Dismantle the sensor cle...

Page 70: ...ghtening torques for components The specified tightening torques of the bolted connections must be observed Tightening torques for assembly devices Unless otherwise described the screws and nuts of the assembly devices supplied by ABB must be tightened in such a way that they are tight fitting WARNING Suspended loads Loads that are not attached according to regulations can cause injury to personne...

Page 71: ...entification of the assembly devices Not all assembly devices are marked with a part number Identification is guaranteed by the tool list This list is enclosed with the toolbox WARNING Servicing the assembly devices Assembly devices must be checked for damage before and after use u Visually inspect for corrosion cracks deformation and wear u Damaged assembly devices must no longer be used and must...

Page 72: ...270 L A275 L A280 L 01 Filter silencer 180 230 350 470 850 1150 02 Wall insert 130 160 300 450 760 1070 03 Diffuser 25 25 40 60 110 160 04 Compressor cas ing 165 215 400 620 1030 1350 05 Cover ring 15 15 30 50 75 90 06 Nozzle ring 8 8 10 20 25 50 07 Gas inlet casing 135 135 180 240 380 520 Table 28 Weights of assemblies kg The total weight of the complete wall insert is made up of the wall insert ...

Page 73: ...mbly Assembly of the filter silencer casing This chapter applies only to turbochargers with filter silencer casing Only the assembly of the filter silencer casing is described in detail The disassembly must be carried out in reverse order of the assembly Fig 26 Dismantling the filter silencer casing 01 02 Bottom part 03 04 07 08 Side part 05 06 09 Circumferential part 10 11 Flange The complete fil...

Page 74: ...ilencer casing assembly Only this way is it possible to fit all the parts u Do not tighten the screws during assembly Fig 27 Fitting the filter silencer casing u Fit the bottom part 01 on the filter silencer 81000 with screws A and B NOTICE Screw A The location of screw A serves as a reference for the correct assembly of the filter silencer casing u Before disassembling the bottom part 01 mark the...

Page 75: ...r 2021 Fig 28 Fitting the filter silencer casing u Fit the bottom part 02 with the screws on the filter silencer Fig 29 Fitting the filter silencer casing u Fit the side parts 03 and 04 with the screws on the filter silencer and on the bottom part u 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 Page 75 145 ...

Page 76: ... All rights reserved HZTL4036_EN Rev T December 2021 Fig 30 Fitting the filter silencer casing u Insert the flanges 10 and 11 laterally between the side parts and fit the screws Fig 31 Fitting the filter silencer casing u Fit the circumferential part 05 with the screws u Fit the circumferential part 06 with the screws Page 76 145 ...

Page 77: ...ndividual parts to the filter silencer Screws for fastening the individual parts M10 30 Nm M8 25 Nm Table 30 Tightening torques filter silencer screws u Tighten all screws of the bottom parts 01 and 02 u Tighten all screws of the side parts 03 04 07 08 and the flanges 10 11 u Tighten all screws of the circumferential parts 05 06 09 Bellows Fig 32 Fitting the bellows u Fit bellows C with frame F sc...

Page 78: ...Welded filter silencer Cast filter silencer The filter silencers differ in terms of the fixing eyelets for the lifting gear The relevant vari ant must be taken into consideration for disassembly and assembly 9 5 2 Dismantling the filter silencer welded u Dismantle the insulation if necessary Fig 33 Dismantling the filter silencer 1 Attach lifting gear to the eyelets of the filter silencer 81000 2 ...

Page 79: ...6_EN Rev T December 2021 9 5 3 Dismantling the filter silencer cast u Dismantle the insulation if necessary Fig 34 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 Page 79 145 ...

Page 80: ... Secure the wall insert 77000 with a hexagon nut 72004 2 Use the press off screws 90900 to press off the wall insert from the compressor cas ing 72000 until the lifting device 90190 can be fitted 3 Remove four threaded studs 72002 at the top so that the lifting device can be fitted 4 Fit shackle 90195 with lifting gear on P1 of lifting device 5 Fit lifting device with crane on upper area of wall i...

Page 81: ...4036_EN Rev T December 2021 Fig 36 Moving out wall insert 7 Carefully move out the wall insert 77000 with diffuser 79000 8 Remove O ring 77040 Fig 37 Putting down wall insert u Put down wall insert 77000 with diffuser 79000 in horizontal position and use appro priate supports to prevent it from falling over and rolling away Page 81 145 ...

Page 82: ...th screwed into the com pressor casing 72000 2 Loosen and remove the remaining screws 72011 3 Use the press off screws 90900 to press off the wall insert 77000 from the com pressor casing 72000 until the lifting device 90190 can be fitted 4 Fit shackle 90195 with lifting gear on P1 of lifting device 90190 5 Fit lifting device 90190 with crane on upper area of wall insert 77000 6 Change the positio...

Page 83: ... T December 2021 Fig 39 Moving out wall insert 7 Remove screw 72011 8 Carefully move out the wall insert 77000 with diffuser 79000 9 Remove O ring 77040 Fig 40 Putting down wall insert u Put down wall insert 77000 with diffuser 79000 in horizontal position and use appro priate supports to prevent it from falling over and rolling away Page 83 145 ...

Page 84: ... even to fatal accidents u Check the position of the support and correct if necessary WARNING Risk of tipping If the wall insert is not tilted it must be put down correctly Tipping of the wall insert may lead to serious injuries to persons or even to fatal accidents u If the wall insert is not tilted ensure that it is fixed correctly see Dis mantling wall insert Fig 41 Putting down wall insert 1 P...

Page 85: ...insert and diffuser Copyright 2021 ABB All rights reserved HZTL4036_EN Rev T December 2021 Fig 42 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 Page 85 145 ...

Page 86: ...rotect against mechanical hazards CAUTION Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts u Have the components assessed and if necessary replaced by an ABB Tur bocharging Service Station Fig 43 Measuring axial clearance A The axial clearance A of the rotor should always be measured before and after...

Page 87: ...NOTICE Dry cleaning The dry cleaning does not have to be removed to dismantle the insulation Fig 44 Removing the insulation A275 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 Page 87 145...

Page 88: ... should be contacted u If a threaded stud 51086 works loose when removing the nut 51087 it should be refit ted after disassembling the gas outlet casing up to the stop in the gas inlet casing until hand tight u If the nut 51087 cannot be removed with the maximum permissible loosening torque it can be heated or removed with an appropriate tool 1 Treat nuts 51087 with rust remover 2 Loosen crosswise...

Page 89: ...ring A275 L Copyright 2021 ABB All rights reserved HZTL4036_EN Rev T December 2021 9 10 Dismantling the nozzle ring A275 L Fig 46 Dismantling the nozzle ring A275 L and smaller 1 Loosen screws 56014 and remove with washers 56011 2 Remove and put down nozzle ring 56001 Page 89 145 ...

Page 90: ...isassembling the gas outlet casing up to the stop in the gas inlet casing until hand tight u If the nut 51087 cannot be removed with the maximum permissible loosening torque it can be heated or removed with an appropriate tool 1 Dismantle both halves of the insulation segment 51215 and remove with all fixing ele ments 2 Detach flange connection between gas inlet casing 51001 and bellows 3 Treat nu...

Page 91: ...0 L Copyright 2021 ABB All rights reserved HZTL4036_EN Rev T December 2021 9 12 Dismantling the nozzle ring A280 L Fig 48 Fitting the nozzle ring holder 1 Remove screws B2 2 Fit the nozzle ring holder 90477 with screws B1 at the top of the flange of the gas inlet casing 51001 Page 91 145 ...

Page 92: ...ng 1 Loop around the nozzle ring holder 90477 with the lifting gear and secure it to the crane 2 Loosen screws 56014 and remove with washers 56011 3 Pull the nozzle ring 56001 towards the front onto the nozzle ring holder 4 Screw the screws B2 into the nozzle ring holder 5 Remove screws B1 Fig 50 Put down the nozzle ring u Use the crane to remove and put down the nozzle ring 56001 Page 92 145 ...

Page 93: ... grease u Coat the screw threads with high temperature grease Fig 51 Fitting the nozzle ring A275 L and smaller Product Size Tightening torque Nm A255 L M10 35 A260 L M10 35 A265 L M10 35 A270 L M10 35 A275 L M10 35 Table 34 Tightening torque 56014 1 Align the notch A1 with the flange connection A2 and slide the nozzle ring 56001 into the gas inlet casing 51001 2 Fit screws 56014 with high tempera...

Page 94: ...torque Nm A255 L M16 301 140 A260 L M16 301 140 A265 L M16 301 140 A270 L M18 401 200 A275 L M22 501 380 Table 35 Tightening torque 51087 1 Pre tightening torque of the nuts 1 Coat threaded stud 51086 with high temperature grease screw in up to the stop in the gas outlet casing 61001 and tighten hand tight 2 Loop around the gas inlet casing 51001 with the lifting gear and secure it to the crane 3 ...

Page 95: ...swise ini tially to the pre tightening torque and then to the tightening torque 6 Remove the lifting gear 7 Connect the flange of the gas inlet casing and the bellows 9 15 Fitting the insulation A275 L Fig 53 Fitting the insulation A275 L and smaller 1 Fit flange connection between gas inlet casing 51001 and bellows 2 Fit the insulation jackets 51200 on the gas inlet casing 51001 with the screws 3...

Page 96: ...021 ABB All rights reserved HZTL4036_EN Rev T December 2021 9 16 Fitting the nozzle ring A280 L u Coat the screw threads with high temperature grease Fig 54 Fitting the nozzle ring A280 L u Use lifting gear to secure the nozzle ring 56001 on the nozzle ring holder 90477 and transport it Page 96 145 ...

Page 97: ...m Table 36 Tightening torque 56014 1 Fit the nozzle ring holder 90477 on the flange of the gas inlet casing 51001 with screws B1 2 Remove screws B2 3 Align the notch A1 on the cam of the nozzle ring 56001 with the flange connection A2 and slide the nozzle ring into the gas inlet casing 4 Coat screws 56014 with high temperature grease and fit with washers 56011 5 Remove screws B1 along with the noz...

Page 98: ... casing 61001 and tighten hand tight 2 Loop around the gas inlet casing 51001 with the lifting gear and secure it to the crane 3 Dismantle and remove supports 90481 90482 from the gas inlet casing 4 Push gas inlet casing over the threaded studs up to the gas outlet casing 5 Coat two nuts with high temperature grease and fix gas outlet casing in two opposite positions 6 Coat remaining nuts with hig...

Page 99: ... against mechanical hazards CAUTION Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts u Have the components assessed and if necessary replaced by an ABB Tur bocharging Service Station Fig 57 Measuring axial clearance A The axial clearance A of the rotor should always be measured before and after servi...

Page 100: ...ing torque Nm A255 L M5 6 A260 L M5 6 A265 L M5 6 A270 L M6 10 A275 L M8 25 A280 L M8 25 Table 39 Tightening torque 77015 1 Attach lifting gear L to the diffuser 79000 2 Carefully place the diffuser on the wall insert 77000 then remove lifting gear 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...

Page 101: ...9 20 Fitting wall insert Copyright 2021 ABB All rights reserved HZTL4036_EN Rev T December 2021 9 20 Fitting wall insert Fig 59 Positioning wall insert u Carefully bring wall insert 77000 into vertical position with the lifting device 90190 Page 101 145 ...

Page 102: ... the wall insert 77000 2 Fit two guide studs 90320 in the upper area of the compressor casing 72000 Leave the top threaded hole x in the compressor casing empty 3 Align arrow markings of wall insert 77000 and compressor casing to one another 4 Carefully move the wall insert with diffuser 79000 over the guide studs into the com pressor casing Check the correct alignment of the wall insert and the c...

Page 103: ...sert fully in and remove the guide studs Fit the remaining threaded studs Observe tightening torque Leave the top threaded hole x in the compressor cas ing empty 8 Check that 23 threaded studs have been fitted 9 Press the wall insert into the compressor casing using a hexagon nut 72004 and sleeve 90191 Observe tightening torque Remove nuts and sleeves Page 103 145 ...

Page 104: ...the upper area of the compressor casing 72000 3 Align arrow markings of wall insert 77000 and compressor casing to one another 4 Carefully move the wall insert with diffuser 79000 over the guide studs into the com pressor casing Check the correct position of both casings using the marking arrows 5 Fit a screw 72011 as a safeguard 6 Remove the shackle 90195 with lifting gear Change the position of ...

Page 105: ...9 21 Fitting the filter silencer 9 21 1 Design variants The turbocharger is equipped with one of the following filter silencer variants Welded filter silencer Cast filter silencer The filter silencers differ in terms of the fixing eyelets for the lifting gear The relevant vari ant must be taken into consideration for disassembly and assembly Page 105 145 ...

Page 106: ...g 62 Fitting the filter silencer Product Size Tightening torque Nm A255 L M16 265 A260 L M16 265 A265 L M14 130 A270 L M16 200 A275 L M18 300 A280 L M20 420 Table 43 Tightening torque 72004 1 Attach lifting gear to the eyelets of the filter silencer 81000 2 Position filter silencer on compressor casing 3 Fit nuts 72004 with washers 72003 and tighten u Fit insulation as far as necessary Page 106 14...

Page 107: ... Fig 63 Fitting the filter silencer Product Size Tightening torque Nm A265 L M14 130 A270 L M16 200 A275 L M18 300 A280 L M20 420 Table 44 Tightening torque 72004 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 u Fit insulation as far as necessary Page 107 145 ...

Page 108: ...ssembly 9 22 Table of tightening torques Copyright 2021 ABB All rights reserved HZTL4036_EN Rev T December 2021 9 22 Table of tightening torques Fig 64 Overview of tightening torques Fig 65 Overview of speed sensor tightening torque Page 108 145 ...

Page 109: ...130 M16 200 M18 300 M20 420 63a 72002 M16 60 M16 60 M14 40 M16 60 M18 80 M20 100 64 77015 M5 6 M5 6 M5 6 M6 10 M8 25 M8 25 65 56014 M10 35 M10 35 M10 35 M10 35 M10 35 M12 65 66 81125 G1 2 45 G1 2 45 G1 2 45 G1 2 45 G1 2 45 G1 2 45 67 86505 M18x1 5 150 M18x1 5 150 M18x1 5 150 M18x1 5 150 M18x1 5 150 M27x2 320 Table 45 Overview of tightening torques 1 Tighten crosswise 2 Pre tightening torque of the...

Page 110: ...he turbocharger is only permissible in emergencies It is not permitted to lock the rotor for an engine test Seri ous damage to engine or property can be caused by non compliance with the regulations in the event of an emergency u The permissible turbocharger speed for the unlocked turbocharger may not exceed nBmax Take note of the rating plate u After locking the turbocharger contact an ABB Turboc...

Page 111: ...n order to ensure that the engine can continue operation as quickly as possible observe the following instructions 10 2 1 Procedure with one turbocharger installed per engine u Stop the engine u Close off oil supply to defective turbocharger u Dismantle filter silencer see chapter Dismantling the filter silencer 78 u Lock rotor with locking device see chapter Locking the rotor 112 Version Procedur...

Page 112: ... to engine or property can be caused by ex cessive speeds The values provided by the enginebuilder apply to the max imum admissible engine load u Observe the permissible turbocharger speed for the unlocked turbochar ger u Reduce the engine load if necessary u Stop the engine u Close off oil supply to defective turbocharger u Blank off the inlets and outlets of the defective turbocharger see chapte...

Page 113: ...ng device to a fin of the wall insert 77000 and align the hole circle to the drill holes in the compressor wheel 25000 5 Secure the locking device to the compressor wheel with the maximum possible number of screws B1 Observe tightening torque Assembly with at least 6 screws is mandatory The maximum possible number of screws to be fitted B1 varies as the threads in the compressor wheel are partiall...

Page 114: ... the gas outlet casing must be ensured In this case additional washers 01 must be provided in accordance with the following table These washers 01 are not supplied by ABB Fig 67 Ensuring clamping of the cover ring Product h mm d1 mm d2 mm A255 L 3 5 4 0 10 16 A260 L 3 5 4 0 10 16 A265 L 3 5 4 0 13 20 A270 L 3 5 4 0 13 20 A275 L 4 0 5 0 17 28 A280 L 4 0 5 0 21 34 Table 49 Required washers 01 Part n...

Page 115: ...d joint air and ex haust gas receivers The cover plates for the compressor casing outlet gas inlet and gas outlet are not included in the ABB scope of delivery The following figure shows the positions where to fit the cover plates Fig 68 Position of cover plates u Stop the engine u Shut off the supply of lubricating oil to the turbocharger u Blank off flanges of compressor casing outlet 01 gas inl...

Page 116: ...osion Preparations for mothballing WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or con tact with them may be harmful to health u Do not breathe in these substances and avoid contact with the skin u Ensure proper ventilation u Observe the information in the material safety data sheet for the operat ing materials and supplies u ...

Page 117: ...ervice 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 for mothballing If the turbocharger remains attached to the engine see section Taking the engine out...

Page 118: ...he presence of such substance s with sufficient information available to the supplier RoHS2 Directive 2011 65 EC in English only The EU Directive 2011 65 EC recast restricts the use of certain hazardous substances in electrical and electronic equipment RoHS2 Products and related accessories manufac tured by ABB Switzerland Ltd Turbocharging do not fall within the Scope of RoHS2 due to their applic...

Page 119: ...a respiratory mask to protect against dusts Wear safety gloves to protect against mechanical hazards Disposal must be environmentally compatible professional and in compliance with locally applicable regulations The turbocharger consists largely of metal cast iron materials steel nickel steel alloys alu minium and bearing brass Further components are Non metallic materials filter components of fel...

Page 120: ...ging Service Station u If different model variants are not taken into account in this document contact an ABB Turbocharging Service Station The customer spare part sets 97070 97071 are available for the work described in the op eration manual The customer spare part set required depends on the service work being carried out on the turbocharger The parts are only available in the complete set Custo...

Page 121: ...part set 97071 Customer spare part set is required for service work on the turbocharger after 18 000 hours Quantity Designation Part number 1 O ring 77040 1 O ring 79020 1 O ring 79021 Table 52 Customer spare part set 97071 u Dispose of replaced parts and parts that are not reusable in a professional and environ mentally compatible manner Page 121 145 ...

Page 122: ...36_EN Rev T December 2021 13 2 Spare Part Illustrations The spare parts lists shown below are only available in English Bearing casing common parts 42039 42015 42011 42463 42464 42465 61035 42001 42461 42459 42460 42462 42307 42306 42305 42300 42008 Available within the spare part set HZTL443382 Mod B Page 122 145 ...

Page 123: ...ation 42001 Bearing casing 42008 Socket screw 42011 O ring 42015 Sealing cover 42039 Hexagon head screw 42300 Partition wall 42305 O ring 42306 O ring 42307 O ring 42459 Hexagon head screw 42460 Cover 42461 Gasket 42462 Cover 42463 Hexagon head screw 42464 Cover 42465 Gasket 61035 Socket screw Table 53 Spare parts Bearing casing common parts Page 123 145 ...

Page 124: ...d HZTL4036_EN Rev T December 2021 Bearing casing oil tank 42186 42064 42458 42185 42294 42295 42041 Bearing casing common 42456 42047 42041 42458 42553 42059 42457 42552 42557 42455 42453 42452 42454 42451 42450 Available within the spare part set HZTL443381 Mod C Upgrade kit sealing air supply Page 124 145 ...

Page 125: ...2059 Hexagon head screw 42064 Hexagon head screw 42185 Socket screw 42186 O ring 42294 Flap with screws 42295 Pressure adjusting unit 42450 Socket screw 42451 Cover 42452 Valve sleeve 42453 Orifice 42454 Gasket 42455 Flange plate 42456 Socket screw 42457 Gasket 42458 Blind flange 42552 Cover 42553 Flat gasket 42557 Hexagon head screw Table 54 Spare parts Bearing casing oil tank Page 125 145 ...

Page 126: ...021 ABB All rights reserved HZTL4036_EN Rev T December 2021 Cartridge 10900 25012 25014 25013 HZTL443573 Mod A Available within the spare part set Part no Designation 10900 Cartridge 25012 Spinner nose cone 25013 Socket screw 25014 Washer Table 55 Spare parts Cartridge Page 126 145 ...

Page 127: ... 61075 77015 79021 79000 77040 77000 72011 if provided HZTL443258 Mod D Available within the spare part set Part no Designation 61075 Hexagon head screw 72000 Compressor casing 72002 Stud 72003 Washer 72004 Hexagon nut 72011 Hexagon head screw 72013 Screw plug 72060 Insulation 74040 Air outlet silencer 74042 Gasket 74043 Counter sunk screw 77000 Wall insert 77015 Socket screw 77040 O ring 79000 Di...

Page 128: ...200 L 13 Spare parts 13 2 Spare Part Illustrations Copyright 2021 ABB All rights reserved HZTL4036_EN Rev T December 2021 Part no Designation 79020 O ring 79021 O ring Table 56 Spare parts Compressor casing Page 128 145 ...

Page 129: ... 81000 81268 81126 Filter silencer with low noise parts HZTL443366 Mod D Part no Designation 81000 Filter silencer complete 81126 Lock 81135 Silencer body 81136 Absorption segment 81137 Sheet Metal covering 81266 Cover grid 81268 Connecting strip 81270 Tension band 81271 Lock 81300 Insulation 81301 Gasket 81302 Insulating disk 81400 Water connection 81500 Silencer casing Table 57 Spare parts Filte...

Page 130: ...75 51001 51215 51087 56001 51086 51074 56011 56014 HZTL443515 Mod B Available within the spare part set Part no Designation 51001 Gas inlet casing 51074 Screw plug 51075 Screw Plug 51086 Threaded stud 51087 Hexagon nut 51200 Insulation 51215 Insulation segment 56001 Nozzle ring 56011 Washer 56014 Hexagon head screw Table 58 Spare parts Gas inlet casing axial Page 130 145 ...

Page 131: ...74 51001 51215 51087 51075 56001 51086 56011 56014 Available within the spare part set HZTL443256 Mod D Part no Designation 51001 Gas inlet casing 51074 Screw plug 51075 Screw plug 51086 Threaded stud 51087 Hexagon nut 51200 Insulation 51215 Insulation segment 56001 Nozzle ring 56011 Washer 56014 Hexagon head screw Table 59 Spare parts Gas inlet casing radial Page 131 145 ...

Page 132: ...61041 61001 61088 61100 61073 if provided HZTL443257 Mod B Part no Designation 57001 Cover ring 57005 Hexagon head screw 61001 Gas outlet casing 61032 Hexagon head screw 61041 Gasket 61073 Screw plug 61083 Pipe 61084 Hexagon head screw 61085 Hexagon head screw 61086 Hexagon nut 61087 Blind flange 61088 Screw plug 61100 Insulation 68002 Foot TE 68031 Distance sleeve Table 60 Spare parts Gas outlet ...

Page 133: ...106 25009 32109 Available within the spare part set HZTL443574 Mod A only without spinner nose cone Part no Designation 21000 Turbine 21001 Turbine unbladed 21005 Locking plate 21010 Labyrinth sleeve 25000 Compressor wheel 25008 Threaded stud 25009 Ring nut 25011 O ring 29000 Turbine blade 32001 Thrust bearing 32101 Radial bearing 32102 Radial bearing 32105 Floating disc 32106 Axial bearing 32109 ...

Page 134: ...A200 L 13 Spare parts 13 2 Spare Part Illustrations Copyright 2021 ABB All rights reserved HZTL4036_EN Rev T December 2021 Part no Designation 42320 Socket screw Table 61 Spare parts Rotor and bearing parts Page 134 145 ...

Page 135: ...42553 42555 42300 42560 42553 42552 42556 HZTL443339 Mod C Available within the spare part set Upgrade kit sealing air supply Part no Designation 42300 Partition wall 42550 Sealing air pipe 42552 Cover 42553 Flat gasket 42554 O ring 42555 O ring 42556 Socket screw 42557 Socket screw 42559 Socket screw 42560 Plate sealing air 97088 Orifice kit Table 62 Spare parts Sealing air supply for flexible cu...

Page 136: ... HZTL4036_EN Rev T December 2021 Speed measurement 86505 86528 86506 86515 86526 Available within the spare part set if provided HZTL443252 Mod B Part no Designation 86505 Speed sensor 86506 O ring 86515 Cable connector 86526 F I converter 86528 Tachometer Table 63 Spare parts Speed measurement Page 136 145 ...

Page 137: ...ts 13 2 Spare Part Illustrations Copyright 2021 ABB All rights reserved HZTL4036_EN Rev T December 2021 U tube manometer 81050 HZTL443260 Mod C Part no Designation 81050 U tube manometer Table 64 Spare parts U tube manometer Page 137 145 ...

Page 138: ...ht 2021 ABB All rights reserved HZTL4036_EN Rev T December 2021 Turbine dry cleaning radial if provided 51717 51723 51722 51712 51720 51705 51724 51714 51716 51700 51706 51713 51725 51719 51711 51721 51708 51710 51710 51703 51701 51709 51704 51718 HZTL443343 Mod B Page 138 145 ...

Page 139: ... Combined air valve 51705 On off valve 51706 Reducing piece 51708 Screw plug 51709 Reducing piece 51710 Gasket 51711 Connecting plate 51712 Pipe 51713 On off valve 51714 Union bush 51716 Heat protection hose 51717 Plate on insulation of GI casing 51718 Hexagon head screw 51719 Hexagon nut 51720 Stud 51721 Hexagon nut 51722 Sleeve 51723 Heat protection hose 51724 Screw in socket 51725 Pipe Table 65...

Page 140: ...crews 12 94020 Bracket 1 Table 66 Customer tool set 90000 A255 L A260 L A265 L 90000 Designation Quantity 90011 Wooden crate 1 90190 Lifting device 1 90195 Shackle 2 90317 Guide stud 3 90320 Guide stud 3 90900 Press off screw 3 90924 Press off screw 1 94003 Locking device 1 94020 Bracket 1 Table 67 Customer tool set 90000 A265 L A270 L A275 L 90000 Designation Quantity 90011 Wooden crate 1 90190 L...

Page 141: ...320 Guide stud 3 90477 Nozzle ring holder 1 90481 Support left 1 90482 Support right 1 90900 Press off screw 6 90924 Press off screw 1 94003 Locking device 1 94020 Bracket 1 Table 69 Customer tool set 90000 A280 L This tool set 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 t...

Page 142: ...9 Fitting the filter silencer casing 75 Fig 30 Fitting the filter silencer casing 76 Fig 31 Fitting the filter silencer casing 76 Fig 32 Fitting the bellows 77 Fig 33 Dismantling the filter silencer 78 Fig 34 Dismantling the filter silencer 79 Fig 35 Dismantling the wall insert A255 L A260 L 80 Fig 36 Moving out wall insert 81 Fig 37 Putting down wall insert 81 Fig 38 Dismantling the wall insert A...

Page 143: ...nsert A265 L A280 L 104 Fig 62 Fitting the filter silencer 106 Fig 63 Fitting the filter silencer 107 Fig 64 Overview of tightening torques 108 Fig 65 Overview of speed sensor tightening torque 108 Fig 66 Locking the rotor 112 Fig 67 Ensuring clamping of the cover ring 114 Fig 68 Position of cover plates 115 Page 143 145 Page 143 145 ...

Page 144: ...ions during operation Charge air pressure too low 65 Table 23 Malfunctions during operation Charge air pressure too high 66 Table 24 Surging of the turbocharger 66 Table 25 Malfunctions when stopping Runout noises 67 Table 26 Malfunctions when stopping Shortened runout time 67 Table 27 Malfunctions of the speed measurement system 68 Table 28 Weights of assemblies kg 72 Table 29 Weight of wall inse...

Page 145: ...pare parts Gas outlet casing 132 Table 61 Spare parts Rotor and bearing parts 134 Table 62 Spare parts Sealing air supply for flexible cut out 135 Table 63 Spare parts Speed measurement 136 Table 64 Spare parts U tube manometer 137 Table 65 Spare parts Turbine dry cleaning radial 139 Table 66 Customer tool set 90000 A255 L A260 L 140 Table 67 Customer tool set 90000 A265 L 140 Table 68 Customer to...

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ABB A100-L Series, Operation Manual

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