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ABB A135-M55, Original Operation Manual

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ABB A135-M55 Original Operation Manual Download Page 51

Operation Manual / 4 Product description / A130-M.. - A145-M..

2  Removing and Installing / 2.3  Installing the turbocharger

© Copyright 2020 ABB. All rights reserved.

HZTL4031_EN

Rev.L

July 2020

2.3.7

Attaching the support

Fig. 18: Attaching the support

u

If present: Attach support (61301) to engine support or to a connecting piece.

Page 

21

 / 

114

Summary of Contents for A135-M55

Page 1: ...Turbocharging Operation Manual A135 M55 HT599670 English Original Operation Manual Chapter Document ID 1 Introduction HZTL4005_EN_G 2 Safety HZTL4022_EN_E 3 Safety data sheet HT599670 4 Product descri...

Page 2: ...ls and the corresponding operating limits in chapter 3 are jointly defined with the enginebuilder This information is specific to the product Non observance of the recommended replacement intervals an...

Page 3: ...f contents Copyright 2020 ABB All rights reserved HZTL4005_EN Rev G March 2020 Introduction 1 Introduction 2 1 1 Purpose of the manual 2 1 2 Symbols definitions 3 1 3 Storage of new turbochargers and...

Page 4: ...lains 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 5: ...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 Definition of C...

Page 6: ...ctogram 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 oth...

Page 7: ...the sense of the Hazardous Substances Ordinance Nevertheless the following points are to be observed when handling VCIs u Observe specifications in the safety data sheet u Ensure good room ventilation...

Page 8: ...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 Turboch...

Page 9: ...reserved HZTL4005_EN Rev G March 2020 1 4 Contact information Contact information for the ABB Turbocharging Service Stations is available online u Scan the QR code to access our website ABB Switzerla...

Page 10: ......

Page 11: ...andatory signs 3 1 4 Definition of safety instructions 3 1 5 Intended use 4 1 6 Deflagration on gas engines 5 1 7 Warning plates on the turbocharger 6 1 8 Turbocharger rating plate 7 1 9 Periodic chec...

Page 12: ...of insufficient compliance with safety instructions Are a consequence of insufficient or inappropriate performance of maintenance and in spection work The operating company is responsible for definin...

Page 13: ...mask to protect against Dusts Gases Safety helmet Ear protection Table 2 Personal protective equipment to be worn specific to the respective task 1 4 Definition of safety instructions WARNING Definiti...

Page 14: ...re required for operation The turbocharger is solely intended to be operated with a clockwise direction of rotation as viewed from the turbine end The specific operating limits of the turbocharger wer...

Page 15: ...r bocharger or improper operation 1 6 Deflagration on gas engines ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar After a deflagration event ABB Turbo System...

Page 16: ...st always be present in the intended locations and must be legible Fig 1 Warning plate If warning plates are not present in the intended locations or are not legible they must be replaced with new war...

Page 17: ...greed 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...

Page 18: ...bove nMmax and tMmax is not permitted Non observance of the recommended inspection and replacement intervals increases the risk of unpredictable component failures Locations of the rating plates The l...

Page 19: ...ainst mechanical hazards Wear safety helmet Fig 3 Attachment of loads on the crane hook Fig 4 Attachment angle If there are two or more suspension points the attachment angle of 45 must not be ex ceed...

Page 20: ...ecked 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 en...

Page 21: ...running always wear 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...

Page 22: ...ves to protect against thermal hazards Hazards due to rotating parts WARNING Physical hazards Contact with rotating parts can cause severe injury The turbocharger must never be used without the filter...

Page 23: ...l installations u Do not carry out any tests with regard to insulation resistance or voltage on the electrical components 1 13 Safe operation Mechanical hazards during operation During standard operat...

Page 24: ...and insulation can cause serious injuries to per sons or even fatal accidents u Only operate the turbocharger with burst protection fitted and insulation fitted in one of the following permitted vari...

Page 25: ...ave 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 working on the turbocharger t...

Page 26: ...during disassembly assembly maintenance and repair u Observe the procedures for set up service and inspection work and the inspection inter vals u Inform the operating staff before starting any servi...

Page 27: ...e 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 th...

Page 28: ...in the 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...

Page 29: ...peration Manual A135 M55 Safety data sheet Page 1 1 Safety data sheet Copyright 2020 ABB All rights reserved HT599670 December 2020 A135 M55 HT599670 A135 M55 HT599670 873 630 864 600 300 12 50 50 202...

Page 30: ......

Page 31: ...pply 22 3 2 Inspection procedures 24 3 3 Commissioning after taking out of operation 26 4 Monitoring operation 27 4 1 Oil pressure oil temperature 27 4 2 Exhaust gas temperature before turbine 29 4 3...

Page 32: ...casing 89 8 17 Measuring radial clearances N and R 91 8 18 Installing the air inlets 92 8 19 Installing the gas outlet flange 93 8 20 Fitting the insulation of the turbine casing 94 8 21 Installing th...

Page 33: ...estions 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 unde...

Page 34: ...Layout and function of the turbocharger Fig 1 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 Tur...

Page 35: ...ngine cylinders 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 radi...

Page 36: ...ates are not present 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 unr...

Page 37: ...ons of the rating plates Copyright 2020 ABB All rights reserved HZTL4031_EN Rev L July 2020 1 6 Locations of the rating plates Fig 4 Locations of the rating plates One rating plate 01 each is attached...

Page 38: ...harger The weight specified below applies to the heaviest variant possible Depending on the specifica tion the weight specified on the rating plate may be lower than the standard value specified here...

Page 39: ...2 Removing the turbocharger u Disconnect all pipes according to the instructions of the enginebuilder Fig 6 Turbine cleaning nozzle u If present Loosen the turbine cleaning connection The cleaning no...

Page 40: ...ct the plug to the speed sensor 86505 and secure the rolled up cable on the turbocharger This protects the plug from being crushed Fig 7 Removing the turbocharger A Oil cooled bearing casing D Clampin...

Page 41: ...chosen to 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 Looseni...

Page 42: ...not clean 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 r...

Page 43: ...ably it may 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 we...

Page 44: ...sealing is provided by O rings The O rings are not included in the ABB scope of delivery Fig 10 Inserting gaskets into the bracket 01 Bracket 04 Slot for O ring 02 Oil supply 05 O rings 03 Oil drain...

Page 45: ...in Requirements for the threaded rods Fig 12 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...

Page 46: ...es 42190 4 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 at...

Page 47: ...astening the 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 Tighte...

Page 48: ...screws u Do 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 Mak...

Page 49: ...controlled 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 t...

Page 50: ...ilder Version 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 coolin...

Page 51: ...g and Installing 2 3 Installing the turbocharger Copyright 2020 ABB All rights reserved HZTL4031_EN Rev L July 2020 2 3 7 Attaching the support Fig 18 Attaching the support u If present Attach support...

Page 52: ...s specifications regarding the selection of lubricating oil and the oil change intervals 3 1 2 Pre lubrication Pre lubrication must be carried out as follows u Switch on the oil pump u Build up oil pr...

Page 53: ...31_EN Rev L July 2020 3 1 5 Oil orifice in the bearing casing Fig 19 Oil orifice 01 Bearing casing 02 Oil orifice 03 Circlip With an oil inlet pressure of more than 3 bar of overpressure with engine u...

Page 54: ...the oil u 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...

Page 55: ...le values 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 e...

Page 56: ...er pipe Version 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 c...

Page 57: ...tion Pressure at oil inlet upstream of 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 m...

Page 58: ...efore start preheat oil 30 C Table 7 Lubricating oil temperature at the inlet Lubricating oil temperature at the outlet The oil temperature at the outlet is mainly dependant on Lubricating oil tempera...

Page 59: ...lacement intervals 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...

Page 60: ...rger speed 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 4 3 2 Layout and overview F...

Page 61: ...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 temperature...

Page 62: ...ing No additional gasket is required during assembly Fig 21 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 9 Tig...

Page 63: ...distance of 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 w...

Page 64: ...opyright 2020 ABB All rights reserved HZTL4031_EN Rev L July 2020 Suggestion for noise insulation bellows Fig 22 Noise insulation bellows 01 Compressor casing 02 Bellows 03 Charge air duct scavenging...

Page 65: ...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 Exception...

Page 66: ...rs after commissioning u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en gine is stopped 5 2 3 Service work according to instructions of enginebuilder u Cle...

Page 67: ...ht 2020 ABB All rights reserved HZTL4031_EN Rev L July 2020 5 2 5 Other service work If a protective grid is installed in the gas outlet casing 61001 by ABB Fig 23 Replacing the protective grid u Remo...

Page 68: ...The following 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 P...

Page 69: ...cing the bearing 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 replac...

Page 70: ...he following 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 c...

Page 71: ...nlet before turbocharger 27 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 procedur...

Page 72: ...suring max imum fuel efficiency Maintenance inter val Maintenance work Operating status 24 72 h 1 Cleaning the compressor during operation 43 Engine load 50 85 50 200 h 1 Cleaning the turbine during o...

Page 73: ...charging recommends mechanical cleaning of the contaminated components Periodic cleaning during operation is not a substitute for the service work during which the turbocharger is completely dismantle...

Page 74: ...erating periods in the lower range of performance that both turbocharger compressors are cleaned 6 2 4 Function and safety of wet cleaning CAUTION Volume of water Uncontrolled volumes of water can dam...

Page 75: ...ved by the mechanical action of the impacting droplets 6 2 5 Carrying out wet cleaning of the compressor Fig 24 Carrying out wet cleaning of compressor Engine load Filling amount of water pressure ves...

Page 76: ...Cause and consequences 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 c...

Page 77: ...nded This cleaning process is faster and reduces the risk of surging of the tur bocharger 6 3 4 Function and safety of wet cleaning CAUTION Corrosion and deposits when cleaning Salt water and cooling...

Page 78: ...gas tem perature 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 cl...

Page 79: ...ume flow VW on the basis ofthe cleaning parameters in the table see Table 14 Wet cleaning of turbine parameters 49 u Close the stop valve 02 after 10 minutes u Wait for 10 minutes do not change the lo...

Page 80: ...ve and easily 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 hav...

Page 81: ...r ring if present 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 filte...

Page 82: ...n segments 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 St...

Page 83: ...erial safety 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...

Page 84: ...oid 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 Wear personal protective equipment PPE acc...

Page 85: ...n hot water or in a liquid such as brake cleaner to soften the contamination u Brush away the contamination or remove with a steam cleaner u Repeat the soaking and brushing process if necessary u Use...

Page 86: ...ing to the following description 6 4 6 Cleaning the cartridge group on compressor end CAUTION Selection of the cleaning agent Cleaning agents which contain chlorine attack metals u Use only pH neutral...

Page 87: ...n the following Fig 29 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 15 Value table for soaking To soak the layers of contaminati...

Page 88: ...and damage 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 imme...

Page 89: ...lead to rotor 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 a...

Page 90: ...Turbocharging Service Station Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Contact enginebuilder Table 17 Malfunctions when starting Vibrations Rubbing of rotating part...

Page 91: ...n 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 Lubricati...

Page 92: ...water too high Check clean cooling system Insufficient ventilation Improve ventilation Table 22 Malfunctions during operation Exhaust gas temperature too high Charge air pressure too low Engine perfor...

Page 93: ...erely contaminated 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 fol...

Page 94: ...cause clarified 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 Re...

Page 95: ...28 Malfunctions 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...

Page 96: ...hapter Ordering spare parts 106 Replacing the speed sensor 32 Table 30 Malfunction of the speed measurement system No signal or poor signal amplitude Measured speed too high Possible causes Remedy Tur...

Page 97: ...safety gloves 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 Wea...

Page 98: ...e the required tool set is available see chapter Tools 111 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 Ser...

Page 99: ...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 hazards Wear safety helmet Definition of terms Sus...

Page 100: ...5 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 4 7 11 07 Cartridge group 40 60 110 180 08 Nozzle r...

Page 101: ...oving the air inlets u Mark the casing position for assembly Fig 33 Removing the air inlets 1 Attach lifting gear to the filter silencer 81000 or air suction branch 82000 2 Loosen and remove V clamp 7...

Page 102: ...ntling and fitting 8 5 Removing the gas outlet casing Copyright 2020 ABB All rights reserved HZTL4031_EN Rev L July 2020 8 5 Removing the gas outlet casing Removing the insulation Fig 34 Removing the...

Page 103: ...301 from bracket 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 8 6 Removing the gas outlet flange Depending o...

Page 104: ...ssary for 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 36 Dismantling the ga...

Page 105: ...ssary for 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 37 Removing the gas o...

Page 106: ...1 Loosen screws 72011 and remove together 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...

Page 107: ...ZTL4031_EN Rev L July 2020 Dismantling the wall insert Fig 39 Dismantling the wall insert 1 Knock the wall insert 77000 out of the compressor casing 72000 with a plastic tip hammer 2 Attach swivel lif...

Page 108: ...0 8 8 Pressing 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...

Page 109: ...ets 01 02 03 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 val...

Page 110: ...s Ripp washers 51003 together with fastening strips 51002 Fig 44 Removing cartridge group 2 3 Insert screws from service support into cartridge group 4 Secure ring nuts VRM onto the screws with washer...

Page 111: ...N Rev L July 2020 8 10 Removing the nozzle ring Fig 45 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 560...

Page 112: ...2020 ABB All rights reserved HZTL4031_EN Rev L July 2020 8 11 Installing the cartridge group on the service support Fig 46 Installing the cartridge group on the service support 1 Remove ring nuts VRM...

Page 113: ...0 1 37 A145 M 0 15 0 25 0 88 1 56 Table 37 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 cl...

Page 114: ...he heat shield 42400 and the turbine casing 51000 Fig 48 Nozzle ring compression PD 42001 Bearing casing 51000 Turbine casing 42400 Heat shield 56001 Nozzle ring Product Nozzle ring compression PD mm...

Page 115: ...ing 56005 in 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...

Page 116: ...it by 90 Fig 50 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 the service support from...

Page 117: ...A130 M8 25 A135 M10 45 A140 M12 75 A145 M12 75 Table 39 Tightening torque 51007 1 Coat thread of studs 51006 with high temperature grease 2 Align the casing position of the cartridge group to the mar...

Page 118: ...is removed 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 insulat...

Page 119: ...41 u Always 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...

Page 120: ...35 A135 M10 70 A140 M12 105 A145 M14 170 Table 41 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 compre...

Page 121: ...sh the feeler 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...

Page 122: ...alling the air inlets Product Size Tightening torque Nm A130 M12 60 A135 M12 60 A140 M12 60 A145 M12 60 Table 43 Tightening torque 72020 1 Secure lifting gear to filter silencer 81000 2 Fit a new O ri...

Page 123: ...d HZTL4031_EN Rev L July 2020 8 19 Installing the gas outlet flange Fig 56 Installing the gas outlet flange 1 If present Insert the metal C ring 57003 into the turbine casing 51000 and secure with hig...

Page 124: ...lation of the turbine casing Copyright 2020 ABB All rights reserved HZTL4031_EN Rev L July 2020 8 20 Fitting the insulation of the turbine casing Fig 57 Fitting the insulation u Fit the insulation acc...

Page 125: ...e Tightening torque Nm A130 M8 20 A135 M10 40 A140 M12 65 A145 M12 65 Table 44 Tightening torque 51009 1 Insert a new gasket 61002 into the gas outlet casing 61001 2 Coat the threads of the studs 5100...

Page 126: ...21 Installing the gas outlet casing Copyright 2020 ABB All rights reserved HZTL4031_EN Rev L July 2020 Fitting the insulation Fig 59 Fitting the insulation u Fit the insulation according to the illust...

Page 127: ...35 A140 A145 02 72020 M12 60 Nm M12 60 Nm M12 60 Nm M12 60 Nm 04 79041 M6 8 Nm 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 1...

Page 128: ...nections Position 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...

Page 129: ...compatible 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 di...

Page 130: ...idge group 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 o...

Page 131: ...ing section 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 62 Fitting the cover plate u...

Page 132: ...be manufactured by the operating company according to the following drawing Material General structural steel in accordance with DIN EN 10025 2 Fig 63 Cover plate drawing Product B1 0 5 B2 B3 B4 0 2 B...

Page 133: ...aring parts are largely protected against corrosion Preparations for mothballing WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or...

Page 134: ...rts are dismantled by an ABB Turbocharging Service Station and stored separately The turbocharger is completely removed either as a whole unit or in individual parts For the measures always necessary...

Page 135: ...ear 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 applica...

Page 136: ...ent model variants are not 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 manne...

Page 137: ...Operation Manual 4 Product description A130 M A145 M 12 Spare parts 12 2 Required customer spare part set 97070 Copyright 2020 ABB All rights reserved HZTL4031_EN Rev L July 2020 Page 107 114...

Page 138: ...are parts 12 3 View of turbocharger with part numbers Copyright 2020 ABB All rights reserved HZTL4031_EN Rev L July 2020 12 3 View of turbocharger with part numbers Fig 64 Overview of part numbers onl...

Page 139: ...C ring 57210 Burst ring 61001 Gas outlet casing 61002 in the customer spare part set Gasket 61200 Burst protection 61205 Protective grid 61301 Support 72000 Compressor casing 72011 Hexagon head screw...

Page 140: ...s reserved HZTL4031_EN Rev L July 2020 12 4 View of turbine cleaning device 12 4 1 One cleaning nozzle per turbine inlet Fig 65 Overview of part numbers Part number Designation 51301 1 inlet 1 cleanin...

Page 141: ...required 90000 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 51 Customer to...

Page 142: ...parts 53 Fig 28 Turbine end non rotating parts 55 Fig 29 Soaking the turbine end 57 Fig 30 Swivel lifting eyes 68 Fig 31 Starpoint ring nut VRM 69 Fig 32 Weights of assemblies 70 Fig 33 Removing the a...

Page 143: ...Operation Manual 4 Product description A130 M A145 M Figures Copyright 2020 ABB All rights reserved HZTL4031_EN Revision L July 2020 Fig 65 Overview of part numbers 110 Page 113 114 Page 113 114...

Page 144: ...s during operation Exhaust gas temperature too high 62 Table 23 Malfunctions during operation Charge air pressure too low 62 Table 24 Malfunctions during operation Charge air pressure too high 63 Tabl...

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