ABB A130 Operation Manual Download Page 1

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Turbocharging

Operation Manual / A135-M66

HT608054

Document identification

Document number

HZTL4031

Revision

Language

English

Original Operation Manual

Product identification

Serial number

HT608054

Customer part number

1006365741

Delivery date (yyyy-mm-dd)

2021-11-29

Weight

300

Operating limits according to rating plate

Speed limit in test rig operation only

Mmax

864

1/s

Speed limit during operation

Bmax

850

1/s

Gas inlet temperature limit in test rig operation only

Mmax

650

°C

Gas inlet temperature limit during operation

Bmax

620

°C

Summary of Contents for A130

Page 1: ...ion Serial number HT608054 Customer part number 1006365741 Delivery date yyyy mm dd 2021 11 29 Weight 300 kg Operating limits according to rating plate Speed limit in test rig operation only nMmax 864...

Page 2: ......

Page 3: ...ation on gas engines 16 2 7 Warning plates on the turbocharger 17 2 8 Turbocharger rating plate 18 2 9 Periodic check of the pressure vessels 20 2 10 Lifting of loads 21 2 11 Prerequisites for operati...

Page 4: ...Removing the gas outlet casing 94 9 6 Removing the gas outlet flange 95 9 7 Removing the compressor casing 98 9 8 Pressing off the casing 100 9 9 Removing the cartridge group 101 9 10 Removing the noz...

Page 5: ...he turbocharger 125 11 1 Taking the engine out of operation for up to 12 months 125 11 2 Taking the engine out of operation for more than 12 months 126 12 Disposing of turbocharger components 127 13 S...

Page 6: ...plains the turbocharger and contains instructions for safe opera tion The Operation Manual is a complement to and expansion of existing national regulations for occupational safety accident prevention...

Page 7: ...m turbocharging 1 3 Essential information Design variants This document is valid for different design variants of turbochargers There may be sections and descriptions of components that are not releva...

Page 8: ...function of the turbocharger Fig 2 Layout and function of the turbocharger 01 Filter silencer air suction branch 08 Gas outlet flange 02 Compressor casing 09 Nozzle ring 03 Diffuser 10 Turbine casing...

Page 9: ...nders The rotor runs in two radial plain bearings 06 which are located in the bearing casing 04 between the compressor and turbine The axial thrust bearing 05 is located between the two radial plain b...

Page 10: ...acilitates the work Definition of mandatory signs Mandatory signs show the protective equipment to be worn for a task The mandatory signs are described in chapter Safety and must be complied with Defi...

Page 11: ...togram Meaning Tighten with specified torque Tighten over specified tightening angle Hand tight tighten without tools Oil Apply screw locking paste e g Loctite Apply high temperature grease Apply othe...

Page 12: ...RNING Health protection when handling VCI VCI products are not hazardous in terms of the Ordinance on Hazardous Substances Nevertheless the following points must be observed when handling VCI u Observ...

Page 13: ...e the turbocharger must be inspected by an ABB Turbocharging Service Station and repacked u Inspect the package for damage If the package is damaged the turbocharger must be in spected by an ABB Turbo...

Page 14: ...roduction 1 7 Registered trademarks Copyright 2021 ABB All rights reserved HZTL4031_EN Rev N March 2021 1 7 Registered trademarks The trademarks of outside companies are used in this document These ar...

Page 15: ...are a consequence of insufficient compliance with safety instructions are a consequence of insufficient or inappropriate performance of maintenance and in spection work The operating company is respo...

Page 16: ...ory mask to protect against Dusts Gases Safety helmet Ear protection Table 3 Personal protective equipment to be worn specific to the respective task 2 4 Definition of safety instructions WARNING Defi...

Page 17: ...operated with a clockwise direction of rotation as viewed from the turbine end The specific operating limits of the turbocharger were determined on the basis of informa tion from the enginebuilder abo...

Page 18: ...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 Positio...

Page 19: ...resent in the designated 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 Clea...

Page 20: ...with the en ginebuilder 02 Turbocharger operating limits during operation Recommended inspection and replacement intervals of turbocharger components 03 Inspection interval of plain bearings in 1000...

Page 21: ...lacement intervals In such cases we recommend contacting the nearest ABB Turbochar ging Service Station nMmax tMmax normally apply only when running at overload 110 during trials on the engine test be...

Page 22: ...locally applicable legal regulations regarding periodic checks of the pressure vessels must be observed The operating company is responsible for the safe operation of the pressure vessel WARNING Dange...

Page 23: ...mechanical hazards Wear safety helmet Fig 9 Attachment of loads on the crane hook Fig 10 Attachment angle If there are two or more suspension points the attachment angle of 45 must not be ex ceeded T...

Page 24: ...ation 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 t...

Page 25: ...ar 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 flu...

Page 26: ...viding protection against contact with hot surfaces u Compliance with the instructions and specifications given by the en ginebuilder to protect against hot turbocharger surfaces is compulsory Wear sa...

Page 27: ...al characteristics to the responsible department immediately u In case of damage take the turbocharger out of operation immediately and safeguard against accidental unauthorised use u When switching o...

Page 28: ...perations for which you have received instruction or train ing Wear safety footwear to protect against mechanical hazard and risk of fall ing Wear protective clothing WARNING Risk of falling When work...

Page 29: ...Observe the material safety data sheet for the cleaning agent or solvent u Wear personal protective equipment PPE according to the material safety data sheet u Inspect the electric cables for abrasion...

Page 30: ...ns 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...

Page 31: ...e 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...

Page 32: ...ocharger The weight specified below applies to the heaviest variant possible Depending on the specification the weight specified on the rating plate may be lower than the standard value specified here...

Page 33: ...ormed when screwing in the screw connection 02 and during subsequent opera tion Reuse of the cleaning nozzle after loosening the screw connection 02 can lead to a water leak or the cleaning nozzle bre...

Page 34: ...to the speed sensor 86505 and secure the rolled up cable on the turbocharger This protects the plug from being crushed Fig 14 Removing the turbocharger A Oil cooled bearing casing D Clamping nut B Wa...

Page 35: ...undo the connection Oil cooled bearing casing A u Attach lifting gear to the suspension eye u Loosen and remove nuts E If clamping nut D is present Loosen in accordance with chapter Loosening the clam...

Page 36: ...pressure screws The pressure screws are equipped with a permanent sliding layer that must not be removed In case of non compliance it cannot be ensured that the necessary tension force is reached u Do...

Page 37: ...tip over This can result in serious personal injury u Place the turbocharger on a clean level support u Secure the turbocharger to prevent it from tipping over by using wooden beams and wedges and by...

Page 38: ...s provided by O rings The O rings are not included in the ABB scope of delivery Fig 17 Inserting gaskets into the bracket 01 Bracket 04 Slot for O ring 02 Oil supply 05 O rings 03 Oil drain 06 Pin opt...

Page 39: ...ments for the threaded rods Fig 19 Requirements for threaded rods Product Diameter Threaded rod mm Material DIN ISO 898 Part 1 Thread length L1 mm Oil cooled L2 mm Water cooled L2 mm A130 16 M16 10 9...

Page 40: ...Attach the lifting gear to the suspension eye of the bearing casing A B and loop around the gas outlet casing 61001 If the gas outlet casing is already fitted in the exhaust gas pipe the attachment of...

Page 41: ...e turbocharger with a standard nut u Fit the nuts and tighten them according to variant 1 or 2 in the table below Product Through hole in bearing casing mm Fixing screws mm Variant 1 Tightening torque...

Page 42: ...o not lubricate pressure screws In order to correctly fit the clamping nuts the pressure screws 04 must not protrude from the clamping nuts 03 in the direction of the thrust washer 02 u Make sure the...

Page 43: ...d tightening of the pressure screws 1 Screw in pressure screws crosswise by hand until reaching the stop 2 Tighten pressure screws crosswise to 50 of the tightening torque specified in the table 3 Tig...

Page 44: ...ion with water cooled bearing casing u Fit the water pipes according to the instructions of the enginebuilder Version with compressor wheel cooling CAUTION Failure of compressor wheel cooling Any prol...

Page 45: ...lling 3 3 Installing the turbocharger Copyright 2021 ABB All rights reserved HZTL4031_EN Rev N March 2021 3 3 7 Attaching the support Fig 25 Attaching the support u If present Attach support 61301 to...

Page 46: ...ations regarding the selection of lubricating oil and the oil change intervals 4 1 2 Pre lubrication Pre lubrication must be carried out as follows u Switch on the oil pump u Build up oil pressure u D...

Page 47: ...March 2021 4 1 5 Oil orifice in the bearing casing Fig 26 Oil orifice 01 Bearing casing 02 Oil orifice 03 Circlip With an oil inlet pressure of more than 3 bar of overpressure with engine under load u...

Page 48: ...For the initial commissioning phase and after all service work flush the complete lubricating system with warm oil u Use special running in filters when running in the engine and after all ser vice w...

Page 49: ...Leaktightness of pipes WARNING Risk of burning from hot gas Escaping gases are hot and will lead to serious burns in the event of contact u Check all pipes for leaks in accordance with the enginebuild...

Page 50: ...sion with compressor wheel cooling u Remove the screw plug on the cooling air connection and fit the cooling air line General u Check the exhaust gas pipe before and after the turbine for combustion r...

Page 51: ...the turbocharger bar Overpressure Normal operation 2 0 poil 4 5 Engine start Cold oil admissible for a maximum of 15 minutes 8 0 Engine idling admissible for a maximum of 1 hour 0 5 poil 2 5 Pre lubri...

Page 52: ...preheat oil 30 C Table 9 Lubricating oil temperature at the inlet Lubricating oil temperature at the outlet The oil temperature at the outlet is mainly dependant on Lubricating oil temperature and pr...

Page 53: ...ntervals Operation above the operating limits defined on the rating plate can shorten the recommended replacement intervals considerably u Measure exhaust gas temperature upstream of turbine u Comply...

Page 54: ...CAUTION Do not strain cables If you pull the speed measurement cables too hard contacts can be pulled out u Do not strain the speed measurement cables by pulling 5 3 2 Layout and overview Fig 27 Layou...

Page 55: ...t 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 a...

Page 56: ...tional gasket is required during assembly Fig 28 Replacing the speed sensor Part number A130 A135 A140 A145 86505 M12 x 1 5 15 Nm M12 x 1 5 15 Nm M12 x 1 5 15 Nm M12 x 1 5 15 Nm Table 11 Tightening to...

Page 57: ...1 meter from the turbocharger The highest value of the emission sound pressure level1 reaches a maximum of 105 dB A near the filter silencer The following prerequisites must be fulfilled with regard...

Page 58: ...21 ABB All rights reserved HZTL4031_EN Rev N March 2021 Suggestion for noise insulation bellows Fig 29 Noise insulation bellows 01 Compressor casing 02 Bellows 03 Charge air duct scavenging air duct 0...

Page 59: ...d 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 stresse...

Page 60: ...ommissioning u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en gine is stopped 6 2 3 Service work according to instructions of enginebuilder u Clean or repl...

Page 61: ...All rights reserved HZTL4031_EN Rev N March 2021 6 2 5 Other service work If a protective grid is installed in the gas outlet casing 61001 by ABB Fig 30 Replacing the protective grid u Remove the prot...

Page 62: ...ng operating data and measured values must be entered regularly in the engine logbook of the enginebuilder Rating and speed of the engine Air intake temperature Pressure of the charge air Pressure los...

Page 63: ...earing parts and replacing the non rotating components exposed to hot gas A decisive role is played by various influencing parameters which in extreme cases can drastically reduce the replacement inte...

Page 64: ...g influences Fuel quality and fuel treatment Load profile thermal cycling also number of starts stops emergency shutdowns oper ating point Gas inlet temperature Frequency and execution of cleaning pro...

Page 65: ...turbocharger 49 Post lubricate water cooled bearing casings until the rotors come to a standstill Deac tivate post lubrication as soon as the rotor comes to a standstill Deviating procedures must be...

Page 66: ...imum fuel efficiency Maintenance inter val Maintenance work Operating status 24 72 h 1 Cleaning the compressor during operation 65 Engine load 50 85 50 200 h 1 Cleaning the turbine during operation 6...

Page 67: ...ecommends mechanical cleaning of the contaminated components Periodic cleaning during operation is not a substitute for the service work during which the turbocharger is completely dismantled and clea...

Page 68: ...riods in the lower range of performance that both turbocharger compressors are cleaned 7 2 4 Function and safety of wet cleaning CAUTION Volume of water Uncontrolled volumes of water can damage the tu...

Page 69: ...mechanical action of the impacting droplets 7 2 5 Carrying out wet cleaning of the compressor Fig 31 Carrying out wet cleaning of compressor Engine load Filling amount of water pressure vessel dm3 Wa...

Page 70: ...onsequences of contamination ABB Turbocharging recommends the use of fuels with low ash sulphur sodium and vana dium contents The combustion of heavy fuel oil HFO in diesel engines causes contaminatio...

Page 71: ...leaning process is faster and reduces the risk of surging of the tur bocharger 7 3 4 Function and safety of wet cleaning CAUTION Corrosion and deposits when cleaning Salt water and cooling water treat...

Page 72: ...ature after the cylinder This must be taken into account when setting the operating point before cleaning If necessary the engine performance must be reduced to meet these conditions The clean ing cyc...

Page 73: ...on the basis ofthe cleaning parameters in the table see Table 16 Wet cleaning of turbine parameters 71 u Close the stop valve 02 after 10 minutes u Wait for 10 minutes do not change the load during t...

Page 74: ...ily sustain mechanical dam age The use of needle descalers for example or other striking tools dam ages the components Depending on the specification nozzle rings or tur bine casings may have protecti...

Page 75: ...resent u Remove filter ring 81265 u Clean filter ring 81265 as required or every 500 hours of operation and replace after the fifth cleaning process at the latest Contamination of the filter ring depe...

Page 76: ...81136 must only be cleaned lightly with compressed air a soft brush or a moist cleaning cloth u Have any heavily contaminated absorption segments replaced by an ABB Turbocharging Service Station Fitt...

Page 77: ...ty data sheet u Comply with local legislation Wear safety goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mask to protect against gases The following parts which are...

Page 78: ...y with local legislation Wear safety goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mask to protect against gases Baked layers of contamination from heavy fuel oil o...

Page 79: ...51301 needs to be replaced u If the screw connection 02 has been loosened a new cleaning nozzle 51301 must be installed and the screw connection must be refit ted Observe the specified tightening tor...

Page 80: ...turbocharger and damage parts inside the cartridge group u Make sure that no water or contamination can enter into the cartridge group u Cleaning procedures should be selected that do not result in re...

Page 81: ...owing Fig 36 Soaking the turbine end Product A mm B mm C mm A130 108 17 205 A135 128 20 245 A140 157 25 300 A145 187 30 357 Table 17 Value table for soaking To soak the layers of contamination on the...

Page 82: ...parts inside the cartridge group u Place the cartridge group on suitable supports 01 made of wood or metal u Observe dimension B for the supports 01 so that the cartridge group is not immersed too de...

Page 83: ...otor unbal ance This can result in bearing or turbocharger damage u Remove all traces of contamination from the turbine u After brushing off the dirt fill the container 02 with clean water and not wit...

Page 84: ...ing Service Station Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Contact enginebuilder Table 19 Malfunctions when starting Vibrations Rubbing of rotating parts Normal be...

Page 85: ...il filter heavily contaminated Clean Oil pump in lubricating system defect ive Check replace Manometer displays incorrectly Replace manometer Table 21 Malfunctions during operation Lubricating oil pre...

Page 86: ...high Check clean cooling system Insufficient ventilation Improve ventilation Table 24 Malfunctions during operation Exhaust gas temperature too high Charge air pressure too low Engine performance and...

Page 87: ...minated or corroded compressor wheel can reduce the com pressor wheel s fatigue endurance limit and result in the turbocharger being damaged u Rectify malfunction in accordance with the following tabl...

Page 88: ...rified and remedied immediately by an ABB Turbochar ging Service Station u Have parts assessed for damage and if necessary replaced by an ABB Turbocharging Service Station Possible causes Remedy Turbo...

Page 89: ...tions when stopping Runout noises Runout time too short The runout time must be noted down as a reference Because the runout time depends on the oil viscosity the runout time must always be measured a...

Page 90: ...ging Service Station Replacing the speed sensor 54 Table 32 Malfunction of the speed measurement system No signal or poor signal amplitude Measured speed too high Possible causes Remedy Turbochar ger...

Page 91: ...ves to protect against thermal hazards WARNING Cutting injuries when working on the turbocharger Some parts on the turbocharger may have sharp edges There is a risk of a cutting injury u Wear safety g...

Page 92: ...red tool set is available see chapter Tools 145 Not all tools are marked with a part number Identification is guaranteed by the tool list This list is enclosed with the tool set WARNING Servicing the...

Page 93: ...ar with sufficient load limit u Pay attention to the correct attachment of loads on the crane hook u People must not stand beneath suspended loads Wear safety gloves to protect against mechanical haza...

Page 94: ...35 kg A140 kg A145 kg 01 Filter silencer 19 30 40 65 02 Radial air suction branch 6 8 13 21 03 Axial air suction branch 4 5 6 9 04 Compressor casing 24 40 60 95 05 Wall insert 6 8 15 24 06 Diffuser 3...

Page 95: ...ir inlets u Mark the casing position for assembly Fig 40 Removing the air inlets 1 Attach lifting gear to the filter silencer 81000 or air suction branch 82000 2 Loosen and remove V clamp 72020 3 Remo...

Page 96: ...itting 9 5 Removing the gas outlet casing Copyright 2021 ABB All rights reserved HZTL4031_EN Rev N March 2021 9 5 Removing the gas outlet casing Removing the insulation Fig 41 Removing the insulation...

Page 97: ...acket 4 Remove the gas outlet casing 61001 set it down properly in an appropriate place and secure it 5 Remove and dispose of the gasket 61002 9 6 Removing the gas outlet flange Depending on the way o...

Page 98: ...ervice work u If necessary Treat the centering seat with rust remover through the press off threads and the clearance holes u Mark the casing position for assembly Fig 43 Dismantling the gas outlet fl...

Page 99: ...service work u If necessary Treat the centering seat with rust remover through the press off threads and the clearance holes u Mark the casing position for assembly Fig 44 Removing the gas outlet flan...

Page 100: ...ether with fastening strips 72012 2 Attach swivel lifting eye S to the compressor casing and the lifting gear 3 Remove the compressor casing 72000 and turn it 180 4 Remove and dispose of the O ring 42...

Page 101: ...Rev N March 2021 Dismantling the wall insert Fig 46 Dismantling the wall insert 1 Knock the wall insert 77000 out of the compressor casing 72000 with a plastic tip hammer 2 Attach swivel lifting eye S...

Page 102: ...ing off the casing CAUTION Axial force of the press off tool Using the press off tool 90042 a high level of axial force can be generated If the casing is pressed off with too much force on one side th...

Page 103: ...3 u Mark the casing position for assembly Do not remove oil orifice if present To limit the oil flow rate through the bearing casing during operation engine under load to the admissible values an oil...

Page 104: ...rs 51003 together with fastening strips 51002 Fig 51 Removing cartridge group 2 3 Insert screws from service support into cartridge group 4 Secure ring nuts VRM onto the screws with washers 5 Secure t...

Page 105: ...h 2021 9 10 Removing the nozzle ring Fig 52 Removing the nozzle ring 1 If present Remove the metal C ring 51105 2 Position the fastening strips 51002 in place 3 Pull out the nozzle ring 56001 with the...

Page 106: ...l rights reserved HZTL4031_EN Rev N March 2021 9 11 Installing the cartridge group on the service support Fig 53 Installing the cartridge group on the service support 1 Remove ring nuts VRM 2 Remove s...

Page 107: ...M 0 15 0 25 0 88 1 56 Table 39 Permissible clearances A and B 1 Move the rotor to and fro up to the stop In order to obtain a correct measurement elev ate the turbine a little 2 Measure clearance A a...

Page 108: ...eld 42400 and the turbine casing 51000 Fig 55 Nozzle ring compression PD 42001 Bearing casing 51000 Turbine casing 42400 Heat shield 56001 Nozzle ring Product Nozzle ring compression PD mm A130 M 0 15...

Page 109: ...n the correct slot see detail A1 A2 When doing this pay attention to correct winding of the lamellar sealing ring see detail B 2 Secure the lamellar sealing ring 56005 with adhesive tape 01 3 Place th...

Page 110: ...ridge group and rotating it by 90 Fig 57 Lifting the cartridge group and rotating it by 90 1 Loosen and remove nuts 2 Lift the cartridge group out of the service support 90012 3 Insert the screws of t...

Page 111: ...ize Tightening torque Nm A130 M8 25 A135 M10 45 A140 M12 75 A145 M12 75 Table 41 Tightening torque 51007 1 Coat thread of studs 51006 with high temperature grease 2 Align the casing position of the ca...

Page 112: ...A burst protection is in tegrated into this turbine casing insulation supplied by ABB For turbochargers which were ordered from ABB without insulation or which are equipped with the insulation 02 sepa...

Page 113: ...replace the O ring 77005 see section Spare parts A130 A140 1 Fit new O ring 77005 2 Install the wall insert 77000 in the compressor casing 3 Fit diffuser 79000 with fixing discs 79040 and screws 7904...

Page 114: ...0 70 A140 M12 105 A145 M14 170 Table 43 Tightening torque 72011 1 Fit new O ring 42012 2 Thoroughly clean the fastening strips 72012 before assembly 3 Attach swivel lifting eyes S to compressor casing...

Page 115: ...er gauges 01 into the gap without clearance simultaneously at the top N1 and the bottom N2 2 Calculate clearance N and compare it with the permissible values in the table 3 Push the feeler gauges 01 i...

Page 116: ...e air inlets Product Size Tightening torque Nm A130 M12 60 A135 M12 60 A140 M12 60 A145 M12 60 Table 45 Tightening torque 72020 1 Secure lifting gear to filter silencer 81000 2 Fit a new O ring 81010...

Page 117: ...N Rev N March 2021 9 19 Installing the gas outlet flange Fig 63 Installing the gas outlet flange 1 If present Insert the metal C ring 57003 into the turbine casing 51000 and secure with high vacuum gr...

Page 118: ...turbine casing Copyright 2021 ABB All rights reserved HZTL4031_EN Rev N March 2021 9 20 Fitting the insulation of the turbine casing Fig 64 Fitting the insulation u Fit the insulation according to th...

Page 119: ...g torque Nm A130 M8 20 A135 M10 40 A140 M12 65 A145 M12 65 Table 46 Tightening torque 51009 1 Insert a new gasket 61002 into the gas outlet casing 61001 2 Coat the threads of the studs 51008 with high...

Page 120: ...g the gas outlet casing Copyright 2021 ABB All rights reserved HZTL4031_EN Rev N March 2021 Fitting the insulation Fig 66 Fitting the insulation u Fit the insulation according to the illustration Obse...

Page 121: ...M6 8 Nm M6 8 Nm M6 8 Nm 08 51007 M8 25 Nm M10 45 Nm M12 75 Nm M12 75 Nm 09 51009 M8 20 Nm M10 40 Nm M12 65 Nm M12 65 Nm 11 72011 M8 35 Nm M10 70 Nm M12 105 Nm M14 170 Nm 15 86505 M12 x 1 5 15 Nm M12...

Page 122: ...sition Part number A130 A135 A140 A145 16a 16b 1 M10 40 Nm M10 40 Nm M12 65 Nm M12 65 Nm 16b 2 M8 20 Nm M8 20 Nm M10 40 Nm M10 40 Nm 18 M6 10 Nm M6 10 Nm M6 10 Nm M6 10 Nm 19 M8 25 Nm M8 25 Nm M8 25 N...

Page 123: ...e manner Wear safety gloves to protect against thermal hazards CAUTION Directives for taking out of operation Serious damage to engine or property can be caused by non compliance with the directives f...

Page 124: ...oup Incorrect handling of a cartridge group can damage the turbocharger and cause injuries to persons u Have repairs to the cartridge group carried out by an ABB Turbocharging Service Station only To...

Page 125: ...on Gas outlet casing not removed u Fit the turbine casing into the gas pipe and on the gas outlet casing again u Attach the cover plate see following section Fig 69 Fitting the cover plate u Make sure...

Page 126: ...ctured by the operating company according to the following drawing Material General structural steel in accordance with DIN EN 10025 2 Fig 70 Cover plate drawing Product B1 0 5 B2 B3 B4 0 2 B5 B6 B7 D...

Page 127: ...are largely protected against corrosion Preparations for mothballing WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or con tact w...

Page 128: ...mantled by an ABB Turbocharging Service Station and stored separately The turbocharger is completely removed either as a whole unit or in individual parts For the measures always necessary for prepari...

Page 129: ...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 Th...

Page 131: ...taken into account in this document contact an ABB Turbocharging Service Station u Dispose of placed and unusable parts in an environmentally friendly and professional manner in accordance with the lo...

Page 132: ...172 42168 42166 42196 42197 42012 10900 42194 p 42047 p 42190 42189 p 42201 42188 p p pre assembled Available within the spare part set if provided HZTL443463 Mod A Part no Designation 10900 Cartridge...

Page 133: ...oled 42167 42166 42196 42197 42012 10900 42194 p 42047 p 42189 p 42190 42201 42188 p p pre assembled Available within the spare part set if provided HZTL443464 Mod A Part no Designation 10900 Cartidge...

Page 134: ...02 TW04 51500 TW02 51107 TW04 51102 TW03 51106 TW04 51101 TW03 p pre assembled Available within the spare part set if provided HZTL443204 Mod L Part no Designation 51000 Turbine casing 51002 Fastening...

Page 135: ...21 ABB All rights reserved HZTL4031_EN Rev N March 2021 Part no Designation 51303 Screw plug 51500 Burst protection TW02 TW04 56001 Nozzle ring 56005 Lamellar sealing ring 57002 Gas outlet flange 5700...

Page 136: ...03 TW02 51102 51010 51101 51010 TW02 51101 51500 p pre assembled Available within the spare part set if provided HZTL443220 Mod H Part no Designation 51000 Turbine casing 51002 Fastening strip 51003 V...

Page 137: ...e part Illustrations Copyright 2021 ABB All rights reserved HZTL4031_EN Rev N March 2021 Part no Designation 56005 Lamellar sealing ring 57002 Gas outlet flange 57003 Metal C ring 57210 Burst ring Tab...

Page 138: ...TL4031_EN Rev N March 2021 Gas outlet casing axial GH02 61001 61002 GH02 GHV03 61001 GH02 GHV08 61001 Available within the spare part set only if provided HZTL443467 Mod A Part no Designation 61001 Ga...

Page 139: ...1201 61100 61001 61005 p 61205 61008 61002 p pre assembled Available within the spare part set if provided HZTL443466 Mod B Part no Designation 61001 Gas outlet casing 61002 Gasket 61005 p Screw plug...

Page 140: ...pre assembled Available within the spare part set if provided HZTL443201 Mod E Part no Designation 72000 Compressor casing 72005 p Screw plug 72006 p Gasket 72010 Verbus locking disc 72011 Hexagon he...

Page 141: ...81266 81000 81136 81270 81271 p pre assembled Available within the spare part set HZTL443469 Mod A Part no Designation 81000 Filter silencer complete 81005 Screw plug 81006 Gasket 81010 O ring 81135...

Page 142: ...TL4031_EN Rev N March 2021 Air suction branch axial 82010 82000 82006 82005 82008 82007 Available within the spare part set HZTL443013 Mod D Part no Designation 82000 Air suction branch 82005 Screw pl...

Page 143: ...L4031_EN Rev N March 2021 Air suction branch radial 82010 82005 82006 82000 82008 82007 Available within the spare part set HZTL443012 Mod D Part no Designation 82000 Air suction branch 82005 Screw pl...

Page 144: ...2188 p p pre assembled Available within the spare part set if provided HZTL443373 Mod E Part no Designation 42001 Bearing casing 42005 Sealing bush 42006 Spring type pin 42008 Socket screw 42047 p Scr...

Page 145: ...part set if provided HZTL443374 Mod E Railway and Traction Application Part no Designation 42001 Bearing casing 42005 Sealing bush 42006 Spring type pin 42008 Socket screw 42047 p Screw plug 42056 We...

Page 146: ...hin the spare part set if provided HZTL443465 Mod D Part no Designation 21000 Turbine 21002 Piston riing 21006 Piston ring 21011 Sealing bush for shaft 25000 Compressor wheel 32101 Radial bearing CE 3...

Page 147: ...0000 Designation Quantity 90012 Service support 1 90013 Plastic insert 1 90258 A145 Lifting beam 1 90230 Socket screw 2 90042 Press off tool 1 90070 Extraction device 1 Table 64 Customer tool set 9000...

Page 148: ...speed sensor 54 Fig 29 Noise insulation bellows 56 Fig 30 Replacing the protective grid 59 Fig 31 Carrying out wet cleaning of compressor 67 Fig 32 Carrying out wet cleaning of turbine 71 Fig 33 Clea...

Page 149: ...3 Installing the gas outlet flange 115 Fig 64 Fitting the insulation 116 Fig 65 Installing the gas outlet casing 117 Fig 66 Fitting the insulation 118 Fig 67 Tightening torques 119 Fig 68 Tightening t...

Page 150: ...le 24 Malfunctions during operation Exhaust gas temperature too high 84 Table 25 Malfunctions during operation Charge air pressure too low 84 Table 26 Malfunctions during operation Charge air pressure...

Page 151: ...137 Table 57 Spare parts Compressor casing 138 Table 58 Spare parts Filter silencer 139 Table 59 Spare parts Air suction branch axial 140 Table 60 Spare parts Air suction branch radial 141 Table 61 S...

Page 152: ......

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