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Operation Manual / A150-M58/68

8 Eliminating malfunctions / 8.1 Malfunctions when starting

© Copyright 2022 ABB. All rights reserved.

HZTL4041_EN

Rev.F

February 2022

8

Eliminating malfunctions

8.1

Malfunctions when starting

Delayed start-up

Possible causes

Remedy

Turbochar-
ger

Turbocharger contaminated

Clean (see chapter

Periodic mainten-

Bearing damaged

Contact a Turbo Systems service sta-
tion

Rotor rubbing
Foreign object in the turbocharger

Table 17: Malfunctions when starting – Delayed start-up

Vibrations

Possible causes

Remedy

Turbochar-
ger

Rotor unbalance

Contact a Turbo Systems service sta-
tion

Turbine or compressor damaged
Bearing damaged

Engine

Vibrations from engine

Contact enginebuilder

Table 18: 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 turbine blades to be somewhat shortened. To prevent
significant loss of efficiency, specific tolerances must be fulfilled.

¡

If there is any doubt about the extent of the rubbing, contact a Turbo Sys-
tems service station.

¡

Have a dimension check carried out by a Turbo Systems service station.

Table 19: Malfunctions when starting – Rubbing of rotating parts

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Summary of Contents for A150-M58

Page 1: ...ct identification Serial number HT613306 Customer part number Delivery date yyyy mm dd 2022 05 25 Weight 1200 kg Operating limits according to rating plate Speed limit in test rig operation only nMmax 546 1 s Speed limit during operation nBmax 542 1 s Gas inlet temperature limit in test rig operation only tMmax 650 C Gas inlet temperature limit during operation tBmax 620 C ...

Page 2: ......

Page 3: ... the turbocharger 16 2 7 Turbocharger rating plate 17 2 8 Periodic check of the pressure vessels 19 2 9 Lifting of loads 20 2 10 Prerequisites for operation and maintenance 21 2 11 Hazards during operation and maintenance 22 2 12 Safe operation 24 2 13 Safe maintenance 25 3 Removing and Installing 29 3 1 Turbocharger weight and transportation 29 3 2 Removing the turbocharger 30 3 3 Installing the ...

Page 4: ... inlets 94 10 2 Removing the gas outlet casing 95 10 3 Removing the gas outlet flange 98 10 4 Removing the cartridge group with compressor and turbine casing 99 10 5 Removing the compressor casing 101 10 6 Removing the cartridge group 102 10 7 Installing the cartridge group on the service support 105 10 8 Removing the nozzle ring 106 10 9 Measuring clearance A and B 107 10 10 Nozzle ring compressi...

Page 5: ... 1 Disassembly 145 13 2 Assembly 148 14 Fitting the cleaning nozzles with multi inlet turbine casings 151 15 Taking out of operation at short notice 152 15 1 Possible emergency repairs 152 15 2 Installing the replacement turbocharger 153 15 3 Installing the replacement cartridge group 153 15 4 Fitting the cover plate 154 15 5 Cover plate drawing 155 16 Mothballing the turbocharger 157 16 1 Taking ...

Page 6: ...xplains 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 and environmental protection Target group The Operation Manual is aimed at engineers and trained mechanics responsible for the proper operation of the engine and for the turbocharger connected to it...

Page 7: ... 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 relevant for a specific turbocharger variant Please contact an Turbo Systems Service Station if you have any questions regarding a design variant see Contact information at www abb com turbocharging Accuracy...

Page 8: ...s reserved HZTL4041_EN Rev F February 2022 1 4 Layout and function of the turbocharger Fig 2 Layout and function of the turbocharger 01 Filter silencer air suction branch 06 Gas outlet flange 02 Compressor casing 07 Nozzle ring 03 Diffuser 08 Turbine casing 04 Bearing casing 09 Compressor wheel 05 Turbine Page 6 181 ...

Page 9: ...ed to the engine cylinders The rotor runs in two radial plain bearings which are located between the compressor and the turbine in the bearing casing 04 The axial bearing is also in the form of a plain bearing The plain bearings are connected to a central lubricating oil duct which is normally supplied by the lubricating oil circuit of the engine The oil outlet lies at the deepest point of the bea...

Page 10: ... 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 Caution Warning Caution and warning signs are described in chapter Safety Turbo Systems Turbo Systems Switzerland Ltd is referred to in this document as Turbo Systems Official service stations of Turbo Systems Official service stations are...

Page 11: ...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 other paste in accordance with specifications Oil free grease free and dry Affix Measure Note Visually inspect Please note text for numbered work step See document Dispose of in an environmentally compat...

Page 12: ...ARNING 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 Observe information in material safety data sheet u Ensure proper space ventilation u Do not eat drink or store food at the workplace while working with VCI u Clean hands and face after working with VCI u ...

Page 13: ...r must be inspected by a Turbo Systems service station and repacked u Inspect the package for damage If the package is damaged the turbocharger must be in spected by a Turbo Systems service station and repacked After every 3 years the following work steps must be performed by a Turbo Systems service station Inspect the component Replace the desiccant agent Repackage the component NOTICE 70 field o...

Page 14: ...duction 1 7 Registered trademarks Copyright 2022 ABB All rights reserved HZTL4041_EN Rev F February 2022 1 7 Registered trademarks The trademarks of outside companies are used in this document These are marked with the symbol Page 12 181 ...

Page 15: ... 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 work o...

Page 16: ...tory 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 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 ...

Page 17: ... to be 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 about the intended use These data are given on the rating plate The use of the turbocharger is limited to the specific application released at the time of de livery Turbo Systems accepts no liabil...

Page 18: ...odifications to the turbocharger or improper operation 2 6 Warning plates on the turbocharger Warning plates are affixed at the following locations Fig 6 Warning plate locations If warning plates are not present in the designated locations or not readable proceed as fol lows u Order new warning plates from Turbo Systems service stations u Remove any warning plates that have become unreadable u Cle...

Page 19: ...d 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 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 0...

Page 20: ... contacting the nearest Turbo Systems Service Station nMmax tMmax normally apply only when running at overload 110 during trials on the engine test bed These limit values can also be permitted during operation for special applications Operation above nMmax and tMmax is not permitted Non observance of the recommended inspection and replacement intervals increases the risk of unpredictable component...

Page 21: ...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 Danger due to pressure vessels The operating company must make sure the pressure vessels are in proper working condition and monitor them Necessary repair or maintenance work must be performed promptly and...

Page 22: ...t 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 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...

Page 23: ...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 Modifications to the tu...

Page 24: ...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 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 bu...

Page 25: ...oviding 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 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 allowe...

Page 26: ...nd objects littering the workplace u Check all pipes to and from the turbocharger for damage and leaks before commission ing u Check turbocharger for recognisable damage or defects every 12 hours of operation or at least once a day u Report any damage and any alterations of operational characteristics to the responsible department immediately u In case of damage take the turbocharger out of operat...

Page 27: ... operations 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 working on the turbocharger there is a risk of falling u Do not climb onto the turbocharger or onto attached parts and do not use them as climbing aids u Use suitable climbing aids and working platforms...

Page 28: ...u 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 and damage before and after your cleaning work Safety during disassembly assembly maintenance and repair u Observe the procedures for set up service and inspection work and the inspection inter val...

Page 29: ...ons 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 m...

Page 30: ...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 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 combust...

Page 31: ...installing and transport ing the turbocharger 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 Fig 11 Suspension of complete turbocharger unit A Complete turbocharger unit without gas outlet casing B Complete turbocharger unit with gas outlet casing Product...

Page 32: ...ng nozzle after loosening the screw connection 02 can lead to a water leak or the cleaning nozzle breaking off and thus destroy the turbine u Only loosen the screw connection 02 if the cleaning nozzle 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 33: ... u If present Detach the support 61301 from the engine support 3 2 1 Loosening the clamping nut CAUTION Incorrect procedure can make loosening impossible If individual pressure screws are fully relieved the pressure screws can be come compressed making it impossible to loosen them u Comply with the following steps for loosening the pressure screws CAUTION Do not clean pressure screws The pressure ...

Page 34: ...v F February 2022 Fig 14 Loosening the clamping nut 1 Working in a circle break loose each pressure screw 20 2 Working in a circle loosen each pressure screw by 45 in 4 rounds 3 Working in a circle loosen each pressure screw by 90 in 1 5 rounds until all of the pres sure screws have been relieved u Loosen clamping nut by hand Page 32 181 ...

Page 35: ...ious 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 taking the centre of gravity into account Fig 15 Turbocharger centre of gravity 01 Centre of gravity u Remove the turbocharger from the engine support u Remove and dispose of the O rings 42195 42200 u Set down and secure the turboc...

Page 36: ...forgotten damaged or improperly inserted will lead to oil leaks u Always use new gaskets and insert them carefully into the slot Fig 16 Inserting the gasket 42001 Bearing casing 01a Oil inlet possible variant 42200 O ring 01b Oil inlet possible variant 42195 O ring 02 Oil drain Detail A Screw plug with orifice hole option u Fit the gasket 42200 on the oil inlet screw plug 01a or 01b with the orifi...

Page 37: ...Inserting the threaded rods 1 Lightly oil the surfaces of the threaded rods 42091 2 Screw the threaded rods into the bracket and hand tighten 3 Check dimensions 3 3 3 Placing the turbocharger on the bracket Fig 18 Placing the turbocharger on the bracket u Make sure that covers of the oil and water connections are removed 1 Carefully lower the turbocharger 2 Check dimensions again Page 35 181 ...

Page 38: ...tension force is reached u Do not clean pressure 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 Make sure the pressure screws do not protrude in the direction of the thrust washer Fig 19 Preparing the clamping nut for the tightening procedure 1 Clean ...

Page 39: ... 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 Tighten pressure screws crosswise to 100 of the tightening torque specified in the table 4 Work in a circle to tighten all pressure screws to 100 of the tightening torque specified in the table 5 Tighten ...

Page 40: ...compressor wheel cooling CAUTION Failure of compressor wheel cooling Any prolonged failure of the compressor wheel cooling will shorten the re placement interval of the compressor wheel u Make sure there is an uninterrupted supply of cooling air during opera tion Fig 22 Connecting the compressor cooling air intake u Remove the screw plug on the connection for the compressor wheel cooling 06 and fi...

Page 41: ...cations 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 Do not exceed a pre lubrication time of 2 minutes u Start the engine u Let the oil pump run until the pump driven by the engine generates sufficient pressure 4 1 3 Oil filtering Filtering the lubricat...

Page 42: ...e in the bearing casing Fig 24 Oil orifice 01 Bearing casing 02 Screw plug left or right 03 Screw plug with orifice hole left or right see also Inserting gaskets With an oil inlet pressure of more than 3 bar of overpressure with engine under load up stream of the turbocharger an oil orifice must be installed to reduce the oil pressure Page 40 181 ...

Page 43: ...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 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 ...

Page 44: ...rdance with the enginebuilder s instruc tions Wear safety gloves to protect against thermal hazards 4 2 4 Checks when starting up the engine If present u Measure speed oil pressure and charging pressure at various engine performances u Measure the exhaust gas temperature before and after the turbine u Measure the air temperature before and after the compressor u Compare the measured values with th...

Page 45: ...let and the gas outlet General u Check the exhaust gas pipe before and after the turbine for combustion residues or wa ter residues and clean it Remove any foreign objects that may be present u Check and clean filter silencer or air supply line and remove any foreign objects that may be present u Put engine side oil circulation to the turbocharger into operation u Prepare the turbocharger for oper...

Page 46: ...m of 15 minutes 8 0 Engine idling admissible for a maximum of 1 hour 0 5 poil 2 5 Pre lubrication and post lubrication engine stopped 0 5 poil 1 0 Warning signal n 0 5 x nBmax 1 25 Alarm signal Not admissible Stop the engine immedi ately 0 6 Table 6 Lubricating oil pressure at oil inlet before turbocharger Depending on use of an oil orifice in accordance with the enginebuilder s specifications Arr...

Page 47: ...rature at the outlet The oil temperature at the outlet is mainly dependant on Lubricating oil temperature and pressure at the oil inlet Engine load and turbocharger speed Exhaust gas temperature The maximum admissible oil temperature 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 mon...

Page 48: ...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 with operating limits on rating plate u For a definition and explanations concerning the rating plate refer to chapter Safety Turbocharger rating plate 17 u For operating limits refer to the Operation Manual t...

Page 49: ...d measurement cables under strain by pulling them 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 25 Layout and overview of speed measurement system 86505 Speed sensor 42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F I converter 01 Plug with integrated voltage limiter 86528...

Page 50: ...ped 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 of temperature are found the nearest Turbo Systems service station has to be contacted u C...

Page 51: ...ling lip and an O ring No additional gasket is required during assembly Fig 26 Replacing the speed sensor Part number A150 M58 68 86505 M12 x 1 5 15 Nm Table 9 Tightening torque 86505 u Reduce the engine performance to idling and then stop the engine Pay attention to post lubrication Stopping the engine 57 u Switch off the lubricating oil supply to the turbocharger u Disconnect cable connector 865...

Page 52: ...of 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 en...

Page 53: ... ABB All rights reserved HZTL4041_EN Rev F February 2022 Suggestion for noise insulation bellows Fig 27 Noise insulation bellows 01 Compressor casing 02 Bellows 03 Charge air duct scavenging air duct 04 Insulation cushion 05 Insulation mat at least 15 mm 06 Sheet metal cover Page 51 181 ...

Page 54: ...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 stresses such as a high number of starts and stops harsh envir onmental conditions poor fuel quality or high system vibrations can lead to untimely machine damage even if the prescribed service interva...

Page 55: ... 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 according to instructions of enginebuilder 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 4 Service work according to data on the r...

Page 56: ...wing 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 loss in the charge air cooler Lubricating oil pressure and lubricating oil temperature If present Speed of the turbocharger Air temperature after the compressor and after the charge air cooler Exhaust ...

Page 57: ...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 sig nificantly reduce the replacement interval of these parts During the prescribed periodic service work the individual parts are examined for wear and replaced if necessary Expected replacement intervals h GAS MDO HFO Turbine casing 2500...

Page 58: ...ing 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 process during operation Turbocharger specification System specific operating conditions combustion quality exhaust gas composition For bearing parts Lubricating oil quality oil filtering oil condition...

Page 59: ...t u Observe the oil pressure specified for engine idling see Table 6 Lubricating oil pressure at oil inlet before turbocharger 44 For oil cooled bearing casings post lubricate for 20 minutes if the turbine inlet temper ature tTE exceeds the following values when the engine is stopped 550 C with insulated casing 600 C with non insulated casing At temperatures below the specified values post lubrica...

Page 60: ...g max imum fuel efficiency Maintenance inter val Maintenance work Operating status 24 72 h 1 Cleaning the compressor during operation 59 Engine load 50 85 50 200 h 1 Cleaning the turbine during operation 62 Engine load 20 40 guideline value According to rating plate 2 Cleaning components mechanically 66 Engine stopped Table 11 Maintenance table h Hours of operation 1 If the maintenance intervals a...

Page 61: ... 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 dismantled and cleaned Cause and consequences of contamination The contamination of the compressor stage depends on the degree of purity of the air that is sucked in Deposits can form in the flow channels if salt oil ...

Page 62: ...eriods 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 turbocharger and the en gine u Never connect the water connection directly to a water pipe or a bigger metering container than the one specified by Turbo Systems WARNING Danger due to pressure vessels ...

Page 63: ...he mechanical action of the impacting droplets 7 2 5 Carrying out wet cleaning of the compressor Fig 28 Carrying out wet cleaning of compressor Engine load Filling amount of water pressure vessel dm3 Water temperature C Water injection period s 50 85 0 4 5 30 10 Table 12 Parameters for wet cleaning of compressor u Remove sealing plug 27005 u Fill container with 0 4 dm3 of pure water u Screw in sea...

Page 64: ...nd consequences of contamination Turbo Systems recommends the use of fuels with low ash sulphur sodium and vanadium contents The combustion of heavy fuel oil HFO in diesel engines causes contamination of the tur bine stage Poor quality fuel in conjunction with high exhaust gas temperatures can lead to extremely hard deposits on turbine components Operating states with incomplete combus tion also i...

Page 65: ...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 treatment substances damage and adversely affect turbocharger parts u Never use salt water but only pure water for cleaning To clean the turbine stage during operation water is injected before the nozzle r...

Page 66: ...0 C Stabilisation phase after TTE has been reached 10 minutes Stabilisation phase after turbine clean ing 10 minutes Water supply ensured Water temperature 5 30 C Water pressure overpressure compared to atmosphere pWT 1 5 bar 2 5 bar 2 External air supply recommended recommended External air pressure pPA relative to tur bine inlet pressure PTE PPA PTE 0 5 bar PPA PTE 1 bar Table 13 Turbine wet cle...

Page 67: ... maximum temperature at the turbine inlet is not exceeded during cleaning Fig 30 Carrying out wet cleaning of turbine u Fulfil prerequisites u Ensure that there is a supply of water 01 u Open the stop valve 02 and set the water volume flow VW with a flowmeter 03 see cleaning parameters u Close the stop valve 02 after 10 minutes u Wait for 10 minutes do not change the load during this stabilisation...

Page 68: ...nd corrosion on the components u Pay attention to the specifications in this chapter pertaining to mechan ical cleaning CAUTION Selection of cleaning tools Turbocharger components are sensitive 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 have protect...

Page 69: ...er ring 81265 u Remove the filter ring u Clean the filter ring as required or every 500 hours of operation and replace it after the fifth cleaning process at the latest Contamination of the filter ring depends on the degree of purity of the sucked in air u Rinse the filter ring with water and mild detergent or in the case of heavy contamination soak and carefully push through Rinse in cold water A...

Page 70: ...egments When cleaning note that the absorption segments may only be cleaned lightly with pres surized air a soft brush or a moist cleaning cloth u Have any heavily contaminated absorption segment replaced by a Turbo Systems service station Fitting the filter silencer u Insert the absorption segments 81136 into the sheet metal coverings 81137 u Bend the sheet metal coverings 81137 back to their ori...

Page 71: ...PPE according to the material 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 which are relevant in terms of performance can be cleaned in accord ance with the description below Fig 32 Compressor casing 72000 Compressor casing u Clean the compressor casi...

Page 72: ...sually The surfaces must be flat and even Any deformations or deteriorations of the surface caused by the cleaning process are not permitted u Have damaged diffusers replaced by a Turbo Systems service station 7 4 4 Turbine end non rotating parts WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or con tact with them may be harmful...

Page 73: ...he customer 56001 Nozzle ring 02 Screw connection provided by the cus tomer 56005 Lamellar sealing ring u Dismantle the lamellar sealing ring 56005 in the nozzle ring u Place contaminated parts in 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 clean...

Page 74: ...Water or air can be passed through the piping and into the cleaning nozzle to check whether it is blocked When installed the cleaning nozzle can be mechanically cleaned with a needle Option with 6 nozzle cleaning See Removing and installing 6 nozzle turbine cleaning component optional 145 7 4 5 Cartridge group general CAUTION Corrosion If the cartridge group is not put back into operation immediat...

Page 75: ...tridge group this can impair the function of the 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 removal of the compressor wheel material or cause damage to its surfaces Clean the compressor wheel with a rag or soft brush which has been soaked in wat...

Page 76: ...e turbine end Product A mm B mm C mm A150 200 35 382 Table 16 Value table for soaking To soak the layers of contamination on the turbine the cartridge group can be immersed vertically in a container 02 with fluid u Place the container 02 inside a larger container 03 so that the overflowing fluid can be collected CAUTION Selection of the cleaning agent Cleaning agents that contain chlorine corrode ...

Page 77: ...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 deeply u Let the layers of contamination on the turbine soak for four hours Removing contamination WARNING Health hazard due to soot particles If soot particles enter the eyes or respiratory tract this can be ...

Page 78: ...ibuted residual contamination deposits 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 contamination fill the container 02 with clean water u Immerse the turbine of the cartridge group in clean water so that any loose contamina tion comes off u Lift up the cartridge group and align it horizont...

Page 79: ... Systems service sta tion Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Contact enginebuilder Table 18 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 ...

Page 80: ... Oil filter heavily contaminated Clean Oil pump in lubricating system defect ive Check replace Manometer displays incorrectly Replace manometer Table 20 Malfunctions during operation Lubricating oil pressure too low Speed reduces Possible causes Remedy Turbochar ger Turbine and or nozzle ring severely con taminated Clean see chapter Periodic mainten ance work 58 Rotor components or bearing damaged...

Page 81: ...high Check clean cooling system Insufficient ventilation Improve ventilation Table 23 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 con...

Page 82: ...inated 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 table Possible causes Remedy Turbochar ger Compressor components severely con taminated by the ventilation gases that have been fed in Clean see chapter Periodic mainten ance work 58 Optimize oil separatio...

Page 83: ...fied and remedied immediately by a Turbo Systems service station u Have parts assessed for damage and if necessary replaced by a Turbo Systems service station Possible causes Remedy Turbocharger Filter silencer or diffuser contamin ated Clean see chapter Periodic mainten ance work 58 Heavy contamination deposits in the turbine or in the nozzle ring Engine Protective grating in front of the tur boc...

Page 84: ...ctions 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 at the same oil temperature If the runout time is significantly shorter in comparison to a previous measurement the fol lowing table must be observed Possible causes Remedy Turbochar ger Turbocharger ...

Page 85: ...tems service station Replacing the speed sensor 49 Table 31 Malfunction of the speed measurement system No signal or poor signal amplitude Measured speed too high Possible causes Remedy Turbochar ger Sensor tip contaminated since it is magnetic and can attract metallic particles This reduces the distance to the signal emitting sealing disc which can lead to ampli fication of the noise com ponent a...

Page 86: ...s There is a risk of a cutting injury u Wear safety gloves against mechanical risks when conducting assembly and disassembly work Wear safety gloves to protect against mechanical hazards CAUTION Further work This Operation Manual may be used to carry out only the work described in it Further work that is carried out in an incorrect way can lead to serious damage to the machine u Turbo Systems reco...

Page 87: ...is guaranteed by the tool list This list is enclosed with the tool set WARNING Servicing the tools The tools must be checked for damage before and after use u Visually inspect for corrosion cracks deformation and wear u Damaged tools must no longer be used and must be replaced Swivel lifting eyes Swivel lifting eyes are required for the safe lifting of loads which are not supplied by Turbo Systems...

Page 88: ...Product Thread Length Quantity A150 M58 68 M12 30 6 Table 35 Press off screws Dismantling screw for the optional 6 nozzle turbine cleaning component A dismantling screw 01 is required to dismantle and fit the cleaning nozzles which is not supplied by Turbo Systems Fig 38 Dismantling screw Product Thread Length mm Quantity A150 M58 68 M8 40 1 Table 36 Dismantling screw Page 86 181 ...

Page 89: ...n 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 Suspension point Defined loading point on a component or an assembly blind hole thread eyelet lug Assembly device Devices that are fitted on the turbocharger in order to obtain a suspension point As sembly devices are specially constructed...

Page 90: ...let and gas outlet options the air suction branch or fil ter silencer as well as the gas outlet casing are removed from the turbocharger for the time being The cartridge group the turbine casing and the compressor casing can then be de tached from the engine and dismantled in an assembled state Reassembly is carried out in reverse order A prerequisite is that the interfaces between the alternative...

Page 91: ...be individually dismantled and fitted in the order shown in the illustration The turbine casing and optional gas outlet casing remain on the engine during the process In addition the nozzle ring can also be dismantled fitted with this concept not shown When employing the cartridge concept the turbine casing and the optional gas outlet cas ing remain on the engine Adequate support or suspension of ...

Page 92: ...ling and fitting spe cial tools for fastening strips 141 which in the event of limited accessibility can be used to facilitate the loosening of nuts and the application of tightening torques for the strip connection between the cartridge group and the turbine casing The spanner holder 90165 should only be used for loosening the nuts and applying tighten ing torques for the nuts at the position sho...

Page 93: ...are rounded up standard values Fig 42 Weights of assemblies Designation A150 M58 68 kg 01 Radial air suction branch 35 02 Filter silencer 120 03 Compressor casing with insulation 250 04 Diffuser 18 05 Cartridge group 270 06 Nozzle ring 8 07 Burst ring 11 08 Turbine casing 1 inlet 320 2 inlets 290 3 inlets 300 09 Gas outlet flange 35 10 Gas outlet casing with insulation 160 Table 37 Weights of asse...

Page 94: ...ening torques Fig 43Overview of tightening torques The following tightening torques must be observed for the designated screw fittings Position Part number A150 M58 68 02 72051 M16 275 Nm 04 79041 M6 8 Nm 08 51007 M16 175 Nm 51007 with spanner holder 90165 M16 85 Nm 09 51009 M16 200 Nm 11 72011 M16 275 Nm 15 86505 M12 x 1 5 15 Nm 16a M16 200 Nm Table 38 Tightening torques Page 92 181 ...

Page 95: ...s reserved HZTL4041_EN Rev F February 2022 Fig 44 Tightening torques for insulation The following tightening torques must be observed for the specified bolted connections Position Part number A150 M58 68 16a M16 200 Nm 16b M12 65 Nm 18 M6 10 Nm 19 M8 25 Nm 20 M10 45 Nm Table 39 Tightening torques for insulation Page 93 181 ...

Page 96: ...ith removed air inlet and gas outlet 10 1 Removing air inlets u Mark the casing position for assembly Fig 45 Removing the air inlets 1 Attach lifting gear to the filter silencer 81000 or air suction branch 82000 2 Loosen the hexagon head screws 72051 and remove them with fastening strips 72012 3 Remove the filter silencer 81000 or air suction branch 82000 4 Remove and dispose of the O ring 81010 o...

Page 97: ...ition for assembly Variant without support Fig 46 Remove gas outlet casing without support 1 If present Remove waste gate pipe 2 Remove insulation ring 3 Fit swivel lifting eyes S to the gas outlet casing 61001 Attach lifting gear to swivel lift ing eye and secure to a crane hook 4 Loosen and remove nuts 51009 5 Remove the gas outlet casing 61001 set it down properly in an appropriate place and se...

Page 98: ... Rev F February 2022 Variant with support Fig 47 Removing gas outlet casing with support 1 1 If present Remove waste gate pipe 2 Remove gas outlet casing insulation 3 Remove insulation ring 4 Remove fixing screws of support 61301 to bracket 5 Fit swivel lifting eyes S to the gas outlet casing 61001 Attach lifting gear to swivel lift ing eye and secure to a crane hook Page 96 181 ...

Page 99: ...g Copyright 2022 ABB All rights reserved HZTL4041_EN Rev F February 2022 Fig 48 Removing gas outlet casing with support 1 6 Loosen nuts 51009 and remove together with support 61301 7 Remove the gas outlet casing 61001 set it down properly in an appropriate place and secure it 8 Remove and dispose of the gasket 61002 Page 97 181 ...

Page 100: ...ure that the gas outlet flange does not cant 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 49 Removing the gas outlet flange Product Press off screws to be used strength 8 8 Tightening torque A150 M58 68 6x M12 x 30 65 Nm Table 40 Press off screws gas outlet flange not included in the Turb...

Page 101: ...oving the cartridge group with compressor and turbine casing Fig 50 Turbine cleaning nozzle 1 If present Loosen the turbine cleaning connection The cleaning nozzle 51301 must be replaced after each removal procedure If the clean ing nozzle is not to be replaced the screw connection 01 must not be loosened during disassembly Fig 51 Remove insulation 2 Remove the compressor casing insulation 3 Remov...

Page 102: ...86505 and secure the rolled up cable on the turbocharger This protects the plug from being crushed 6 Attach lifting gear to the cartridge group and secure to a crane 7 Loosen the clamping nut see Loosening the clamping nut 31 Fig 53 Setting down the cartridge group with the compressor and turbine casing 8 Lift the cartridge group with the compressor and turbine casing 9 Fit two swivel lifting eyes...

Page 103: ...ratch protection not included in the Turbo Systems scope of delivery If the compressor casing cannot be loosened it can be pressed off against the turbine cas ing with the press off tool 90042 90022 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 4 ...

Page 104: ... Mark the casing position for assembly Fig 55 Removing cartridge group 1 Product Position Tightening torque Nm A150 M58 68 01 150 Table 41 Tightening torque 90012 01 1 Treat threads of studs 51006 with penetrating oil and leave to take effect 2 Loosen nuts 51007 and remove Verbus Ripp washers 51003 together with the fasten ing strips 51002 3 Fit the cross piece of the service support 90012 Observe...

Page 105: ...the cartridge group cannot be loosened the press off tool 90042 can be used 4 Secure the first set of lifting gear to the bearing casing 5 Secure the second set of lifting gear to the service support with a swivel lifting eye The length of the lifting gear must be selected in such a way that the compressor wheel is not touched when turning the cartridge group 6 Remove the cartridge group verticall...

Page 106: ... cartridge group Copyright 2022 ABB All rights reserved HZTL4041_EN Rev F February 2022 Fig 57 Removing cartridge group 3 7 Place a suitable protective cover over the compressor wheel 8 Turn the cartridge group into the horizontal rotor axis 9 Remove lifting gear from service support and cross piece Page 104 181 ...

Page 107: ...pport Copyright 2022 ABB All rights reserved HZTL4041_EN Rev F February 2022 10 7 Installing the cartridge group on the service support Fig 58 Installing the cartridge group on the service support 1 Assemble the service support 90012 with longitudinal and cross pieces 2 Fit service support to cartridge group 3 Put down cartridge group Page 105 181 ...

Page 108: ...let 10 8 Removing the nozzle ring Copyright 2022 ABB All rights reserved HZTL4041_EN Rev F February 2022 10 8 Removing the nozzle ring Fig 59 Removing the nozzle ring 1 Pull out the nozzle ring 56001 with the two extraction devices 90070 2 Remove the lamellar sealing ring 56005 Page 106 181 ...

Page 109: ... 80 1 39 Table 42 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 and compare it with the permissible values in the table 3 Raise the compressor and push the turbine down at the same time 4 Raise the turbine and push the compressor down at the same time 5 Measure clearance B and c...

Page 110: ...peration it must be clamped between the heat shield 42400 and the turbine casing 51000 Fig 61 Nozzle ring compression PD 42001 Bearing casing 51000 Turbine casing 42400 Heat shield 56001 Nozzle ring Product Nozzle ring compression PD mm A150 M58 68 0 17 0 17 Table 43 Nozzle ring compression PD 1 Measure dimensions A B and S on cleaned surfaces 2 Calculate compression PD u If the calculated value P...

Page 111: ...F February 2022 10 11 Installing nozzle ring Fig 62 Installing the nozzle ring 1 Fit the lamellar sealing ring 56005 see A A When doing this pay attention to correct winding of the lamellar sealing ring see detail B 2 Align the cams on the nozzle ring with the recesses of the turbine casing 51000 3 Insert the nozzle ring 56001 into the turbine casing up to the stop Page 109 181 ...

Page 112: ...artridge group Copyright 2022 ABB All rights reserved HZTL4041_EN Rev F February 2022 10 12 Installing the cartridge group Fig 63 Lifting the cartridge group and rotating it by 90 1 Fasten lifting gear to cartridge group and lift cartridge group 2 Remove service support 90012 3 Dismantle service support Page 110 181 ...

Page 113: ...e Nm A150 M58 68 01 150 Table 44 Tightening torque 90012 01 4 Re fit the cross piece of the service support 90012 Observe the tightening torque 5 Place the protective cover over the compressor wheel 6 Secure the second set of lifting gear to the cross piece with a swivel lifting eye The length of the lifting gear must be selected in such a way that the compressor wheel is not touched 7 Turn the ca...

Page 114: ...roup Product Size Tightening torque Nm A150 M58 68 M16 175 Table 45 Tightening torque 51007 8 Coat the threads of the studs 51006 with high temperature grease 9 Align casing position of cartridge group with marking and lower into the turbine casing 10 Remove lifting gear cross piece of service support 11 Install the fastening strips 51002 with Verbus Ripp washers 51003 and hexagon nuts 51007 Obser...

Page 115: ...22 10 13 Installing the compressor casing Fitting the diffuser Fig 66 Fitting the diffuser Product Size Tightening torque Nm A150 M58 68 M6 8 Table 46 Tightening torque 79041 1 Secure the diffuser 79000 with fixing discs 79040 and new screws 79041 Observe the tightening torque 2 Fit lifting gear with swivel lifting eye S to compressor casing 72000 and rotate the compressor casing by 180 Page 113 1...

Page 116: ...ebruary 2022 Installing the compressor casing Fig 67 Installing the compressor casing Product Size Tightening torque Nm A150 M58 68 M16 275 Table 47 Tightening torque 72011 1 Fit new O ring 42012 2 Thoroughly clean the fastening strips 72012 before assembly 3 Install the compressor casing 72000 4 Install the fastening strips 72012 with screws 72011 Observe the tightening torque Page 114 181 ...

Page 117: ...ridge group with compressor and turbine casing Fig 68 Turning the cartridge group with compressor and turbine casing 1 Attach second lifting gear to bearing casing and secure to the crane hook This lifting gear must be attached during the entire rotating procedure 2 Lift cartridge group with compressor and turbine casing with the first lifting gear and lower it with the second lifting gear 3 Remov...

Page 118: ...stalling the gas outlet flange Fig 69 Installing the gas outlet flange 1 If present Insert the metal C ring 57003 into the turbine casing 51000 and secure with high vacuum grease 2 Fit swivel lifting eye S to the gas outlet flange 57002 Secure lifting gear to the swivel lifting eye 3 Install gas outlet flange in turbine casing 51000 4 Measure radial clearance R see chapter Radial clearances N and ...

Page 119: ...learance and measure 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 into the gap without clearance and measure simultaneously at the top R2 and the bottom R1 4 Calculate clearance R and compare it with the permissible values in the table CAUTION Clearances outside the tolerance Serious damag...

Page 120: ...utlet 10 17 Fitting the insulation Copyright 2022 ABB All rights reserved HZTL4041_EN Rev F February 2022 10 17 Fitting the insulation Fig 71 Fitting the insulation u Fit the insulation according to the illustration Observe tightening torques see Table of tightening torques 92 Page 118 181 ...

Page 121: ...O rings 42195 42200 2 Remove cover from oil inlet and outlet and carefully lower cartridge group with com pressor and turbine casing onto bracket Fig 73 Installing the cartridge group with compressor and turbine casing 3 Mount and tighten the clamping nut see Fastening the turbocharger with a clamping nut 36 4 Remove lifting gear from bearing casing 5 If present Remove the screw plug from the conn...

Page 122: ...able 49 Tightening torque 51009 1 Coat thread of bolts 51008 with high temperature grease 2 Insert a new gasket 61002 into the gas outlet casing 61001 3 Fit swivel lifting eyes S to the gas outlet casing 61001 Secure lifting gear to the swivel lifting eye 4 Place gas outlet casing at turbine casing 51000 Observe the marking 5 Fit hexagon nuts 51009 Observe the tightening torque 6 Fit insulation ri...

Page 123: ...t 1 Product Size Tightening torque Nm A150 M58 68 M16 200 Table 50 Tightening torque 51009 1 Coat thread of bolts 51008 with high temperature grease 2 Insert a new gasket 61002 into the gas outlet casing 61001 3 Fit swivel lifting eyes S to gas outlet casing 61001 Secure lifting gear to the swivel lift ing eye 4 Place gas outlet casing on the turbine casing 51000 Observe the marking 5 Fit support ...

Page 124: ... Fig 76 Installing gas outlet casing with support 2 7 Fit the screws of the support Tighten in accordance with enginebuilder s specifications 8 Fit insulation ring Observe tightening torques see Table of tightening torques 92 9 Fit gas outlet casing insulation see Table of tightening torques 92 10 If present Attach waste gate pipe Tighten in accordance with enginebuilder s specifica tions Page 122...

Page 125: ...lets Product Size Tightening torque Nm A150 M58 68 M16 275 Table 51 Tightening torque 72051 1 Attach lifting gear to the filter silencer 81000 or air suction branch 82000 2 Fit a new O ring 81010 to the filter silencer 81000 or a new O ring 82010 to the air suction branch 82000 3 Install the filter silencer 81000 or air suction branch 82000 4 Fit the fastening strips 72012 with hexagon head screws...

Page 126: ...artridge concept 11 1 Removing air inlets u Mark the casing position for assembly Fig 78 Removing the air inlets 1 Attach lifting gear to the filter silencer 81000 or air suction branch 82000 2 Loosen the hexagon head screws 72051 and remove them with fastening strips 72012 3 Remove the filter silencer 81000 or air suction branch 82000 4 Remove and dispose of the O ring 81010 or 82010 Page 124 181...

Page 127: ...2 11 2 Removing the compressor casing u Mark the casing position for assembly Fig 79 Removing the compressor casing 1 Remove the compressor casing insulation 2 Fit swivel lifting eye S to the compressor casing 72000 Secure lifting gear to the swivel lifting eye 3 Loosen screws 72011 and remove together with fastening strips 72012 4 Remove the compressor casing 72000 Page 125 181 ...

Page 128: ...l 90042 90022 Fig 80 Pressing off compressor casing 01 Disc as scratch protection not included in the Turbo Systems scope of delivery 1 Remove front turbine casing insulation 2 Press off compressor casing with press off tool 90042 90022 and disk 01 Fig 81 Remove the diffuser 1 Remove and dispose of the O ring 42012 2 Set the compressor casing 72000 down on a suitable support 3 Loosen screws 79041 ...

Page 129: ...insulation sheets u If present Remove the insulation sheets 01 02 03 Fig 83 Removing cartridge group 1 1 Apply two marking lines M to the left and right of the cartridge group and the bracket 2 Support and fix turbine casing and gas outlet casing 3 Loosen the clamping nut 42201 see Loosening the clamping nut 31 4 Use the hexagon to raise the threaded rod 42191 up to its stop 5 Attach lifting gear ...

Page 130: ...uary 2022 Fig 84 Removing cartridge group 2 If the cartridge group cannot be loosened the press off tool 90042 can be used 1 Treat threads of studs 51006 with penetrating oil and leave to take effect 2 Loosen nuts 51007 and remove Verbus Ripp washers 51003 together with fastening strips 51002 3 Pull the cartridge group from the turbine casing and remove it Page 128 181 ...

Page 131: ...B All rights reserved HZTL4041_EN Rev F February 2022 Fig 85 Removing cartridge group 3 1 Unscrew the threaded stud 42191 downwards and remove the clamping nut 42201 2 Remove and dispose of the O rings 42195 42200 3 If present Remove the metal C ring 51105 4 Attach the cartridge group to the service support 90012 Page 129 181 ...

Page 132: ...pt 11 4 Removing the nozzle ring Copyright 2022 ABB All rights reserved HZTL4041_EN Rev F February 2022 11 4 Removing the nozzle ring Fig 86 S_05180 1 Pull out the nozzle ring 56001 with the two extraction devices 90070 2 Remove the lamellar sealing ring 56005 Page 130 181 ...

Page 133: ...Table 52 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 and compare it with the permissible values in the table 3 Raise the compressor and push the turbine down at the same time 4 Raise the turbine and push the compressor down at the same time 5 Measure clearance B and compare it...

Page 134: ... must be clamped between the heat shield 42400 and the turbine casing 51000 Fig 88 Nozzle ring compression PD 42001 Bearing casing 51000 Turbine casing 42400 Heat shield 56001 Nozzle ring Product Nozzle ring compression PD mm A150 M58 68 0 17 0 17 Table 53 Nozzle ring compression PD 1 Measure dimensions A B and S on cleaned surfaces 2 Calculate compression PD u If the calculated value PD lies outs...

Page 135: ... 2022 11 7 Installing nozzle ring Fig 89 Installing the nozzle ring 1 Fit the lamellar sealing ring 56005 see A A When doing this pay attention to correct winding of the lamellar sealing ring see detail B 2 Align the cams on the nozzle ring with the recesses of the turbine casing 51000 3 Insert the nozzle ring 56001 into the turbine casing up to the stop Page 133 181 ...

Page 136: ...2022 11 8 Installing the cartridge group Fig 90 Installing the cartridge group 1 Attach lifting gear to bearing casing 2 Remove the fixing screws and lift cartridge group out of the service support 90012 3 Screw the threaded stud 42191 into the clamping nut 42201 from below as far as its stop 4 Fit new O rings 42195 42200 5 If present Insert the metal C ring 51105 Page 134 181 ...

Page 137: ... access 51007 with a spanner holder see Special tools for fastening strips 141 Product Size Tightening torque Nm A150 M58 68 M16 85 Table 55 Tightening torque 51007 with spanner holder 1 Move the cartridge group into the turbine casing and align with the markings M made on the bracket at the time of disassembly 2 Use the hexagon to screw the threaded rod 42191 down to its stop 3 Tighten pressure s...

Page 138: ...9 Installing the compressor casing Fitting the diffuser Fig 92 Fitting the diffuser Product Size Tightening torque Nm A150 M58 68 M6 8 Table 56 Tightening torque 79041 1 Secure the diffuser 79000 with fixing discs 79040 and new screws 79041 Observe the tightening torque 2 Fit lifting gear with swivel lifting eye S to compressor casing 72000 and rotate the compressor casing Page 136 181 ...

Page 139: ...2 Installing the compressor casing Fig 93 Installing the compressor casing Product Size Tightening torque Nm A150 M58 68 M16 275 Table 57 Tightening torque 72011 u Thoroughly clean the fastening strips 72012 before assembly 1 Fit a new O ring 42012 2 Install the compressor casing 72000 3 Install the fastening strips 72012 with screws 72011 Observe the tightening torque Page 137 181 ...

Page 140: ... gauges 01 into the gap without clearance and measure 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 into the gap without clearance and measure simultaneously at the top R2 and the bottom R1 4 Calculate clearance R and compare it with the permissible values in the table CAUTION Clearances ou...

Page 141: ... Fitting the insula tion Copyright 2022 ABB All rights reserved HZTL4041_EN Rev F February 2022 11 11 Fitting the insulation Fig 95 Fitting the insulation u Fit the insulation according to the illustration Observe tightening torques see Table of tightening torques 92 Page 139 181 ...

Page 142: ...ct Size Tightening torque Nm A150 M58 68 M16 275 Table 59 Tightening torque 72051 1 Attach lifting gear to the filter silencer 81000 or air suction branch 82000 2 Fit a new O ring 81010 to the filter silencer 81000 or a new O ring 82010 to the air suction branch 82000 3 Install the filter silencer 81000 or air suction branch 82000 4 Fit the fastening strips 72012 with hexagon head screws 72051 Obs...

Page 143: ...ing torques for the strip connection between the cartridge group and the turbine casing See also chapter Tools 176 The spanner holder 90165 should only be used for loosening the nuts and applying tighten ing torques for the nuts at the position shown Other screws or nuts on the turbocharger should not be tightened with this tool Customer tool not included in the Turbo Systems scope of delivery Fig...

Page 144: ...the spanner holder 90165 3 Loosen the two nuts on the other side by using the spanner holder 90166 The cartridge group is fitted at this point in time To enable a clear representation of the work step the cartridge group is not illustrated in work step 4 Fig 99 Removing the fastening strips 4 Remove the nuts 51007 with spanner holder 90165 90166 and attached torque span ner 02 Remove washers 51003...

Page 145: ...upper fastening strips 51002 shown in the picture and tighten with the torque spanner 02 without a spanner holder Observe the tightening torque Fig 101 Fitting the bottom fastening strip 2 Position the collection tray 01 to catch any fixing elements if they fall 3 Tighten the two nuts on one side using the spanner holder 90165 4 Tighten the two nuts on the other side using the spanner holder 90166...

Page 146: ...022 ABB All rights reserved HZTL4041_EN Rev F February 2022 Fig 102 Fitting the bottom fastening strip Product Size Tightening torque Nm A150 M58 68 M16 85 Table 62 Tightening torque 51007 with spanner holder 5 Fit the nuts 51007 with spanner holder 90165 90166 and attached torque span ner 02 Observe the tightening torque Page 144 181 ...

Page 147: ...bine cleaning component optional 13 1 Disassembly The following illustration shows the initial situation before the 6 nozzle turbine cleaning component is dismantled Fig 103 Initial situation u Before disassembly mark the positions of the elbows 51311 Fig 104 Disassembly of the elbows 1 Just loosen the union nuts 51316 of the elbows 51311 Do not remove them yet 2 Just loosen the screws 51314 Do no...

Page 148: ... 1 Disassembly Copyright 2022 ABB All rights reserved HZTL4041_EN Rev F February 2022 Fig 105 Disassembly of the elbows u Remove the elbows 51311 from the connecting pieces 51313 in the specified order 01 02 03 04 05 Fig 106 Pipe disassembly 1 Undo union nuts 51316 of pipe 51312 2 Remove pipe Page 146 181 ...

Page 149: ...isassembly of the connecting pieces 1 Unscrew hexagon head screws 51314 from connecting pieces 51313 2 Remove gaskets 51302 3 Remove connecting pieces 4 Remove gaskets from holes Fig 108 Disassembly of the cleaning nozzle u Remove cleaning nozzles 51301 with screw 01 in accordance with the following table Product Thread Length mm Quantity A150 M58 68 M8 40 1 Table 63 Dismantling screw Page 147 181...

Page 150: ...screw 1 Screw the screw 01 into the cleaning nozzle 51301 as far as it will go 2 Insert the cleaning nozzle with screw as far as it will go 3 Rotate the cleaning nozzle clockwise until the cleaning nozzle lowers further and is thus correctly positioned u Remove the screw 01 ensuring that the cleaning nozzle remains in position Fig 110 Assembly of the connecting pieces 1 Position gaskets 51302 on h...

Page 151: ...d contact surfaces of cutting ring with high temperature grease 2 Position pipe 51312 3 Position union nuts 51316 of pipe on connecting piece 51313 and screw in fitting 51305 and tighten by hand only Fig 112 Elbow 1 assembly u Coat thread and contact surfaces of cutting ring with high temperature grease u Screw union nuts 51316 of elbows 51311 in the specified order 01 02 03 04 05 to the connectin...

Page 152: ...ly Copyright 2022 ABB All rights reserved HZTL4041_EN Rev F February 2022 Fig 113 Elbow 2 assembly Product 51314 Nm 51316 Nm A150 M58 68 80 70 Table 65 Tightening torque 51314 51316 1 Tighten hexagon head screws 51314 to tightening torque 2 Tighten union nuts 51316 of elbows 51311 to tightening torque Page 150 181 ...

Page 153: ...ev F February 2022 14 Fitting the cleaning nozzles with multi inlet turbine casings Fig 114 Fit the cleaning nozzles 1 The designation P on the turbine casing must correspond with the designation P on the cleaning nozzle 2 The edges for the defined installation position in the turbine casing and at the cleaning nozzle must correspond Page 151 181 ...

Page 154: ...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 for blanking the turbocharger off the engine u Follow the directives of the enginebuilder If the engine has to be brought back into operation again as quickly as possible in the event of a turbocharger...

Page 155: ...up Incorrect handling of a cartridge group can damage the turbocharger and cause injuries to persons u Always have repairs to the cartridge group carried out by a Turbo Sys tems service station To enable an engine to be put back into operation quickly after a turbocharger has sustained damage Turbo Systems recommends having a replacement cartridge group available in storage The defective cartridge...

Page 156: ...ion 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 115 Fitting the cover plate u Make sure that the oil connections in the bracket are equipped with gaskets 1 Close opening in turbine casing 51000 with cover plate 01 2 Thoroughly clean the fastening strips 51002 before assembly 3 Coat th...

Page 157: ... plate is not included in the Turbo Systems scope of delivery and must be manufac tured by the operating company according to the following drawing Material General structural steel in accordance with DIN EN 10025 2 Fig 116 Cover plate drawing Product B1 0 5 B2 B3 B4 0 2 B5 B6 0 1 B7 ØD1 0 2 ØD2 R1 M A150 138 9 135 240 21 4 2 0 320 71 4 413 6 33 196 M12 Table 66 Cover plate dimensions mm Page 155 ...

Page 158: ...peration at short notice 15 5 Cover plate drawing Copyright 2022 ABB All rights reserved HZTL4041_EN Rev F February 2022 Fig 117 Dimensions for cover plate Product A B D1 D2 0 1 A150 90 10 90 0 2 28 2 Table 67 Cover plate dimensions mm Page 156 181 ...

Page 159: ...corrosion 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 supplie...

Page 160: ...tation 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 of op e...

Page 161: ...stomer of the 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 Turbo Systems Switzerland Ltd do not fall within the Scope of RoHS2 due to their...

Page 162: ...r 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 f...

Page 163: ...e not taken into account in this document contact an Turbo Systems Service Station u Dispose of placed and unusable parts in an environmentally friendly and professional manner in accordance with the local regulations u Dispose of the packaging of new parts in an environmentally friendly and professional manner in accordance with the local regulations 18 2 Required customer spare part set 97070 Fo...

Page 164: ...172 42170 42200 42172 42196 42195 42196 42197 42166 10900 42202 42193 42012 42194 42191 42047 42190 42201 42189 42188 Available within the spare part set if provided HZTL443471 Mod A A150 M58 68 only Part no Designation 10900 Cartridge 42012 O ring 42047 Screw plug 42166 Screw 42167 Cover 42170 Insulation 42172 Hexagon head screw 42188 Hexagon head screw 42189 Gasket 42190 Expansion bush 42191 Thr...

Page 165: ... part Illustrations Copyright 2022 ABB All rights reserved HZTL4041_EN Rev F February 2022 Part no Designation 42196 Orifice oil inlet 42197 Safety ring 42200 O ring 42201 Clamping nut 42202 Screw plug Table 69 Spare parts Cartridge oil cooled Page 163 181 ...

Page 166: ...19 42301 42008 42302 42303 Available within the spare part set p pre assembled if provided HZTL443310 Mod D A150 M58 68 only Part no Designation 42001 Bearing casing 42005 p Sealing bush 42006 p Spring type pin 42008 Socket screw 42019 Hexagon head screw 42020 Washer 42301 Bearing cover 42302 Piston ring 42303 Piston ring 42305 O ring 42306 O ring 42308 O ring 42400 Heat shield Table 70 Spare part...

Page 167: ...n the spare part set if provided HZTL443470 Mod B Part no Designation 21000 Turbine 21002 Piston ring 21006 Piston ring 21011 Sealing bush for shaft 25000 Compressor wheel 32101 Radial bearing 32102 Radial bearing 32103 Thrust ring 32104 Thrust bearing 32109 Sealing disc 32110 Bearing flange 32111 Auxiliary bearing 32112 Bearing flange 32113 Socket screw 32114 Socket screw 32159 Socket screw 32167...

Page 168: ...107 TW04 51101 TW03 if provided HZTL443311 Mod B Part no Designation 51000 Turbine casing 51002 Fastening strip 51003 Verbusripp washer 51006 Stud 51008 Stud 51009 Hexagon nut 51010 o Insulation TW03 TW04 51027 Screw plug 51101 Hexagon head screw 51102 Tension washer 51105 o Metal C ring 51106 Hexagon head screw 51107 o Tension washer 51500 Burst protection 56001 Nozzle ring 56005 Lamellar sealing...

Page 169: ...106 TW04 51101 TW03 if provided HZTL443472 Mod A Part no Designation 51000 Turbine casing 51002 Fastening strip 51003 Verbusripp washer 51006 Stud 51007 Hexagon nut 51008 Stud 51009 Hexagon nut 51010 Insulation 51027 Screw plug 51101 Hexagon head screw 51102 Tension washer 51105 Metal C ring 51106 Hexagon head screw 51107 Tension washer 51500 Burst protection 56001 Nozzle ring 56005 Lamellar seali...

Page 170: ...1102 TW03 51106 TW04 51101 TW03 if provided HZTL443473 Mod A Part no Designation 51000 Turbine casing 51002 Fastening strip 51003 Verbusripp washer 51006 Stud 51008 Stud 51009 Hexagon nut 51010 Insulation 51027 Screw plug 51102 Tension washer 51105 Metal C ring 51106 Hexagon head screw 51107 Tension washer 51302 Gasket 51303 Screw plug 51500 Burst protection 56001 Nozzle ring 56005 Lamellar sealin...

Page 171: ...51302 51303 51313 51309 51312 51314 51305 51308 51304 51310 HZTL443336 Mod B RT01 RT03 RT05 RT07 Part no Designation 51301 Cleaning nozzle 51302 Gasket 51303 Screw plug 51304 Flange 51305 Union branch 51308 Stud 51309 Expansion sleeve 51310 Hexagon nut 51311 Pipe elbow 51312 Pipe 51313 Joining piece 51314 Hexagon head screw 51316 Cap nut 51317 Stop plug Table 75 Spare parts Cleaning device Page 16...

Page 172: ... 61140 61202 61201 61005 p 61001 61301 61002 Available within the spare part set p pre assembled if provided HZTL443312 Mod C Part no Designation 61001 Gas outlet casing 61002 Gasket 61005 p Screw plug 61100 Insulation gas outlet casing GW03 61140 Insulation 61201 Hexagon head screw 61202 Tension washer 61301 Support Table 76 Spare parts Gas outlet casing radial Page 170 181 ...

Page 173: ...p Available within the spare part set p pre assembled HZTL443313 Mod C A150 M58 68 only Part no Designation 72000 Compressor casing 72005 p Screw plug 72006 p Gasket 72011 Hexagon head screw 72012 Fastening strip 72016 Fastening strip 72060 Insulation 72061 Insulation sleeve 72062 Hexagon head screw 72063 Tension washer 77000 Wall insert 77005 O ring 77006 Stud 79000 Diffuser 79040 Fixing washer 7...

Page 174: ...hin the spare part set if provided HZTL443314 Mod C A155 M Decoupled filter silencer only Part no Designation 72052 Hexagon socket set screw 72053 Verbusripp locking disc 72054 Hexagon nut 72055 Fuse 81000 Filter silencer complete 81005 Screw plug 81006 Gasket 81010 O ring 81135 Silencer body 81136 Absorption segment 81137 Cover sheet metal 81145 Flange compressor end 81146 Flange turbine end 8114...

Page 175: ...lter ring 81266 Cover grid 81269 Connection rod 81271 Lock 81272 Hexagon head screw 81273 Hexagon nut Table 78 Spare parts Filter silencer Air suction branch axial 82010 82000 82008 82007 82006 82005 Available within the spare part set HZTL443474 Mod A Part no Designation 82000 Air suction branch 82005 Screw plug 82006 Gasket 82007 Screw plug 82008 Gasket 82010 O ring Table 79 Spare parts Air suct...

Page 176: ...041_EN Rev F February 2022 Air suction branch radial 82010 82000 82006 82008 82007 82005 Available within the spare part set HZTL443315 Mod B Part no Designation 82000 Air suction branch 82005 Screw plug 82006 Gasket 82007 Screw plug 82008 Gasket 82010 O ring Table 80 Spare parts Air suction branch radial Page 174 181 ...

Page 177: ...ABB All rights reserved HZTL4041_EN Rev F February 2022 Speed measurement system 86258 86526 86505 86515 if provided HZTL443475 Mod A Part no Designation 86258 Tachometer 86505 Speed sensor 86515 Cable connector 86526 F I Converter Table 81 Spare parts Speed measurement system Page 175 181 ...

Page 178: ...Press off tool 2 90070 Extraction device 2 Table 82 Customer tool set 90000 Turbo Systems offers an optional special tool set 90160 which in the event of limited ac cessibility can be used to facilitate the loosening of nuts and the application of tightening torques for the strip connection between the cartridge group and the turbine casing Special tool 90160 Fig 118 Special tool Part number Descr...

Page 179: ...ABB All rights reserved HZTL4041_EN Rev F February 2022 Tool sets can be ordered from any Turbo Systems service station The following specifica tions must be included in the order Turbocharger type Designation and part number of the tool set Page 177 181 ...

Page 180: ...rrying out wet cleaning of compressor 61 Fig 29 Turbine cleaning devices 64 Fig 30 Carrying out wet cleaning of turbine 65 Fig 31 Cleaning the filter silencer 67 Fig 32 Compressor casing 69 Fig 33 Diffuser 70 Fig 34 Turbine end non rotating parts 71 Fig 35 Soaking the turbine end 74 Fig 36 Swivel lifting eye example 85 Fig 37 Press off screws 86 Fig 38 Dismantling screw 86 Fig 39 Removing the cart...

Page 181: ...ing cartridge group 1 127 Fig 84 Removing cartridge group 2 128 Fig 85 Removing cartridge group 3 129 Fig 86 S_05180 130 Fig 87 Measuring clearance A and B 131 Fig 88 Nozzle ring compression PD 132 Fig 89 Installing the nozzle ring 133 Fig 90 Installing the cartridge group 134 Fig 91 Installing the cartridge group 2 135 Fig 92 Fitting the diffuser 136 Fig 93 Installing the compressor casing 137 Fi...

Page 182: ...eed in creases 78 Table 23 Malfunctions during operation Exhaust gas temperature too high 79 Table 24 Malfunctions during operation Charge air pressure too low 79 Table 25 Malfunctions during operation Charge air pressure too high 80 Table 26 Malfunctions during operation Engine performance losses 80 Table 27 Malfunction Turbocharger surging 81 Table 28 Malfunction Sporadic surge blows 81 Table 29...

Page 183: ...imensions mm 155 Table 67 Cover plate dimensions mm 156 Table 68 Customer spare part set 97070 161 Table 69 Spare parts Cartridge oil cooled 163 Table 70 Spare parts Bearing casing oil cooled 164 Table 71 Spare parts Rotor and bearing parts 165 Table 72 Spare parts Turbine casing 1 inlet 166 Table 73 Spare parts Turbine casing 2 inlets 167 Table 74 Spare parts Turbine casing 3 inlets 168 Table 75 ...

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