ABB A170-L35 Operation Manual Download Page 1

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ABB Turbocharging

Operation Manual

A170-L35

XAC21898 English

Original Operation Manual

Chapter

Document-ID

Introduction

HZTL4005_EN_G

Safety

HZTL4024_EN_D

Safety data sheet

XAC21898

Product description

HZTL4034_EN_P

Summary of Contents for A170-L35

Page 1: ...rging Operation Manual A170 L35 XAC21898 English Original Operation Manual Chapter Document ID 1 Introduction HZTL4005_EN_G 2 Safety HZTL4024_EN_D 3 Safety data sheet XAC21898 4 Product description HZ...

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: ...2 1 3 Definition of mandatory signs 3 1 4 Definition of safety instructions 3 1 5 Intended use 4 1 6 Warning plates on the turbocharger 5 1 7 Turbocharger rating plate 6 1 8 Periodic check of the pres...

Page 12: ...nce 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 defi...

Page 13: ...y 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 Defini...

Page 14: ...data are given on the rating plate ABB accepts no liability and rejects all warranty claims for any non intended uses WARNING Unapproved operation Any operation of the turbocharger outside of its ope...

Page 15: ...must 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 w...

Page 16: ...herwise agreed with the en ginebuilder 02 Turbocharger operating limits during operation Recommended replacement intervals of turbocharger components 03 Replacement interval of plain bearings in 1000...

Page 17: ...Mmax and tMmax is not permitted Non observance of the recommended replacement intervals increases the risk of unpredict able component failures Locations of the rating plates The locations of the rati...

Page 18: ...against 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 ce...

Page 19: ...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...

Page 20: ...s 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 part...

Page 21: ...loves 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 filt...

Page 22: ...ical installations u Do not carry out any tests with regard to insulation resistance or voltage on the electrical components 1 12 Safe operation Mechanical hazards during operation During standard ope...

Page 23: ...u 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 turbocharge...

Page 24: ...ety 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 se...

Page 25: ...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...

Page 26: ...n 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 materia...

Page 27: ...on Manual A170 L35 Safety data sheet Page 1 1 Safety data sheet Copyright 2020 ABB All rights reserved XAC21898 April 2020 A170 L35 XAC21898 A170 L35 XAC21898 317 550 296 520 2015000450 2020 3300 36 1...

Page 28: ......

Page 29: ...ing after taking out of operation 15 4 Monitoring during operation 16 4 1 Oil pressure oil temperature 16 4 2 Admissible air inlet temperature 19 4 3 Turbocharger speed 19 4 4 Low pressure measurement...

Page 30: ...zzle ring A180 L 73 8 13 Fitting the nozzle ring A175 L 75 8 14 Fitting the gas inlet casing A175 L 76 8 15 Fitting the insulation A175 L 78 8 16 Fitting the nozzle ring A180 L 79 8 17 Fitting the gas...

Page 31: ...tions 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 unders...

Page 32: ...ry 2020 1 4 Layout and function of the turbocharger Fig 1 Layout and function of the turbocharger 01 Filter silencer 08 Gas inlet casing 02 Thrust bearing 09 Bearing casing 03 Radial plain bearing 10...

Page 33: ...r passes through the filter silencer 01 to the compressor wheel 11 The air then flows through the diffuser 10 and exits the turbocharger through the compressor cas ing 12 An air outlet silencer 13 is...

Page 34: ...es 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 unrea...

Page 35: ...f the rating plates Copyright 2020 ABB All rights reserved HZTL4034_EN Rev P January 2020 1 6 Locations of the rating plates Fig 3 Locations of the rating plates One rating plate 01 each is attached o...

Page 36: ...e Product Weight of complete turbocharger unit kg A165 L 2300 A170 L 3300 A175 L 5600 A180 L 7500 A185 L 10500 A190 L 13500 Table 2 Total weight 2 2 Removing the turbocharger WARNING Risk of tipping I...

Page 37: ...ing the turbocharger Copyright 2020 ABB All rights reserved HZTL4034_EN Rev P January 2020 Fig 4 Fit the lifting gear u Loosen fixing screws on compressor end and turbine end foot u Lift turbocharger...

Page 38: ...ing the turbocharger on the bracket Fig 5 Placing the turbocharger u Remove covers from the oil connections u Align turbocharger and place on engine bracket u Tighten the fixing screws Steps for faste...

Page 39: ...a compressor end a height of turbocharger foot a Dimension a turbine end a height of turbocharger foot F spacer sleeve D Dimension b Hole in bracket Dimension c Thread length 1 5 x nominal thread diam...

Page 40: ...7 3100 Table 4 Tightening torques foot screws Angle controlled tightening Product Thread size Height a foot mm Pre tightening torque Nm Tightening angle height a DEG Additional tightening angle for ev...

Page 41: ...ith a filter mesh width of 0 050 mm is sufficient for the tur bocharger 3 1 3 Oil pressure Comply precisely with the oil pressure before the turbocharger for trouble free operation If the oil pressure...

Page 42: ...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 o...

Page 43: ...sembly can liquefy or vaporise and escape as oily fluids during the initial hours of operation Continual escape of an oily fluid indicates an oil leak u If there is a leak contact an ABB Turbocharging...

Page 44: ...up with an oil temperature range at the inlet of 30 65 C with an oil temperature range at the inlet of 65 80 C 0 8 4 0 1 0 4 0 Temporarily admissible 1 h alarm with an oil temperature range at the inl...

Page 45: ...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 b...

Page 46: ...BB Tur bocharging Service Station 4 1 1 Pre lubrication and post lubrication CAUTION Pre lubrication Serious damage to engine or property can result if the turbocharger is not supplied with oil from t...

Page 47: ...d of the turbocharger must be permanently monitored CAUTION Do not use cables as a climbing aid If you pull the speed measurement cables too hard contacts can be pulled out u Do not tension the speed...

Page 48: ...at which the maximum tur bocharger speed does not exceed 70 of nBmax u If the engine cannot be stopped it can continue to be driven at this reduced engine load or turbocharger speed u If a turbocharge...

Page 49: ...d with a sealing lip and does not require a sealing disc for as sembly Fig 10 Replacing the speed sensor Part number A165 L A170 L A175 L A180 L A185 L A190 L 86505 M18x1 5 150 Nm M18x1 5 150 Nm M18x1...

Page 50: ...for the cal culation of the turbocharger efficiency When using a filter mat An increased pressure loss indicates an increase in the fouling of the filter material 4 4 2 U tube manometer at the filter...

Page 51: ...stance 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 rega...

Page 52: ...Service work enables the detection and rectification of changes to the tur bocharger and ensures full operability of the turbocharger CAUTION Service intervals Any service work on the turbocharger th...

Page 53: ...the filter silencer and check for damage u Dismantle the wall insert u Check axial clearance A u Clean compressor wheel diffuser wall insert and compressor casing and check for dam age u Check the no...

Page 54: ...hts reserved HZTL4034_EN Rev P January 2020 u Replace the plain bearing 5 2 5 Service work according to instructions of enginebuilder u Clean or replace the oil filter located in the supply pipe to th...

Page 55: ...g operating data and measured values must be entered regularly into the engine logbook of the enginebuilder Performance and speed of the engine Speed of the turbocharger Air intake temperature Exhaust...

Page 56: ...ement intervals h Turbocharger part Operation with HFO Gas inlet casing 50000 100000 Gas outlet casing 50000 100000 Nozzle ring 35000 50000 Cover ring 25000 50000 Other casings 100000 Table 10 Expecte...

Page 57: ...lations can result in inadmissible turbocharger speeds which can lead to serious damage to property with grave consequences u The air outlet flap and gas inlet flap must be completely open during nor...

Page 58: ...n and service 5 5 Stopping the engine Copyright 2020 ABB All rights reserved HZTL4034_EN Rev P January 2020 5 5 Stopping the engine u Observe the instructions regarding post lubrication Pre lubricatio...

Page 59: ...rved HZTL4034_EN Rev P January 2020 6 Periodic maintenance 6 1 Foreword to maintenance Maintenance work includes regular visual controls and cleaning operations which are inten ded to ensure the troub...

Page 60: ...he filter silencer Filter silencer with tension band Fig 13 Layout and overview of filter silencer 81126 Lock 81266 Cover grid 81135 Body of filter silencer 81268 Connecting strip 81136 Absorption seg...

Page 61: ...d connecting strips 81268 see Fig 13 Layout and overview of fil ter silencer 32 u Pull out insert units E u Bend up the sheet metal coverings 81137 and remove the absorption segments 81136 u Clean the...

Page 62: ...January 2020 6 3 Changing the filter strip on the filter silencer casing This chapter applies only to turbochargers with filter silencer casing The filter ring 81265 is replaced with the filter silen...

Page 63: ...16 Attaching new filter ring u Attach the new filter ring 81265 on the filter ring to be replaced so they overlap Fig 17 Fitting new filter ring u Pull on the old filter ring until the new filter rin...

Page 64: ...creased rotor unbalance Periodic cleaning of the compressor during operation prevents or delays any major increase in contamination But it never replaces the regular service work where the turbocharge...

Page 65: ...compressor stage during operation water is injected upstream of the com pressor wheel The water does not act as a solvent The coating is removed by the mechanical action of the impacting droplets The...

Page 66: ...amage u Always wear ear protection when carrying out wet cleaning on the com pressor Wear ear protection Fig 18 Overview of wet cleaning of compressor 81000 Filter silencer A Can 81126 Lock B Filler o...

Page 67: ...185 L 3 0 A190 L 3 0 Table 12 Volume of water per cleaning process The filling time is 4 15 seconds Checking the filter plug The filter plug only needs to be checked in the turbocharger version with a...

Page 68: ...level of contamina tion can lead to intolerably high rotor unbalance Despite periodic cleaning during operation experience shows that overhauls during which the turbine and nozzle ring or VTG are mech...

Page 69: ...ing device Fig 20 Overview of dry cleaning device 11 Granulate container 51702 16 Protection valve closed 51713 12 Cover cap 51703 17 Pressurised air valve venting 51704 13 Pressurised air supply 4 7...

Page 70: ...emove the cover cap 12 u Fill the specified amount of granulate into the container 11 u Screw on and tighten the cover cap 12 u Open the combined pressurised air valve pressure release valve 17 down l...

Page 71: ...Hard granulated materials such as natural core granulates Soft blast media Activated carbon particles The average grain size of the cleaning granulate must be between 1 2 and 2 0 mm The specific weig...

Page 72: ...er due to other causes the gas outlet casing can be drained Fig 21 Drain pipe diagram 01 Drain pipe A Position 1 02 Drain cock B Position 2 03 Drain 04 Air line from compressor casing u On the drain p...

Page 73: ...ce Station Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Contact enginebuilder Table 16 Malfunctions when starting Vibrations Rubbing of rotating parts Normal behaviour n...

Page 74: ...an environmentally compatible manner Wear safety gloves to protect against thermal hazards Possible causes Remedy Turbochar ger Axial clearance of the rotor excessive Contact an ABB Turbocharging Ser...

Page 75: ...gh Check clean cooling system Insufficient ventilation Improve ventilation Table 20 Malfunctions during operation Exhaust gas temperature too high Charge air pressure too low Engine performance and en...

Page 76: ...Surging of the turbocharger Surging of the turbocharger Possible causes Remedy Turbocharger Filter silencer or diffuser contamin ated Clean Periodic maintenance 31 Heavy dirt deposits in the turbine...

Page 77: ...n of the turbocharger A surge blow is accompanied by a loud bang and escape of hot air from the filter silencer 7 4 Malfunctions when stopping Runout noises Possible causes Remedy Turbochar ger Turboc...

Page 78: ...n electronics This problem will be remedied by removing the gasket Sensor defective Contact ABB Turbocharging Service Station Measured speed too high Contamination of the sensor tip As the sensor tip...

Page 79: ...s are marked with a part number Identification is guaranteed by the tool list This list is enclosed with the toolbox WARNING Servicing the assembly devices Assembly devices must be checked for damage...

Page 80: ...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...

Page 81: ...5 L A180 L A185 L A190 L 01 Filter silencer 240 360 600 800 850 1050 02 Wall insert 240 340 560 820 1090 1500 03 Diffuser 40 60 100 140 200 270 04 Compressor casing 320 450 740 960 1360 1800 05 Cover...

Page 82: ...E Disassembly Assembly of the filter silencer casing This chapter applies only to turbochargers with filter silencer casing Only the assembly of the filter silencer casing is described in detail The d...

Page 83: ...filter silencer casing assembly Only this way is it possible to fit all the parts u Do not tighten the screws during assembly Fig 24 Fitting the filter silencer casing u Fit the bottom part 01 on the...

Page 84: ...P January 2020 Fig 25 Fitting the filter silencer casing u Fit the bottom part 02 with the screws on the filter silencer Fig 26 Fitting the filter silencer casing u Fit the side parts 03 and 04 with...

Page 85: ...silencer casing Copyright 2020 ABB All rights reserved HZTL4034_EN Rev P January 2020 Fig 27 Fitting the filter silencer casing u Insert the flanges 10 and 11 laterally between the side parts and fit...

Page 86: ...screws Screws for fastening the individual parts to the filter silencer Screws for fastening the individual parts M10 30 Nm M8 25 Nm Table 29 Tightening torques filter silencer screws u Tighten all s...

Page 87: ...encers differ in terms of the fixing eyelets for the lifting gear The relevant vari ant must be taken into consideration for disassembly and assembly 8 4 2 Dismantling the filter silencer welded If th...

Page 88: ...ncer cast If the turbocharger is also fitted with a noise package chapter Dismantling the filter silencer with noise package 61 must be observed u Dismantle the insulation if necessary Fig 31 Dismantl...

Page 89: ...lencer u Dismantle the insulation if necessary Fig 32 Dismantling the filter silencer with noise package 1 Loosen and remove the insulation ring 81300 2 Attach the lifting gear to the front lug and re...

Page 90: ...11 and leave 2 3 of the thread length screwed into the com pressor casing 72000 2 Loosen and remove the remaining screws 72011 3 Use the press off screws 90900 to press off the wall insert 77000 from...

Page 91: ...4034_EN Rev P January 2020 Fig 34 Moving out wall insert 7 Remove screw 72011 8 Carefully move out the wall insert 77000 with diffuser 79000 9 Remove O ring 77040 Fig 35 Putting down wall insert u Put...

Page 92: ...sonnel and even to fatal accidents u Check the position of the support and correct if necessary WARNING Risk of tipping If the wall insert is not tilted it must be put down correctly Tipping of the wa...

Page 93: ...tling wall insert and diffuser Copyright 2020 ABB All rights reserved HZTL4034_EN Rev P January 2020 Fig 37 Dismantling the diffuser 4 Loosen and remove screws 77015 5 Remove O rings 79020 79021 6 Att...

Page 94: ...oves to protect against mechanical hazards CAUTION Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts u...

Page 95: ...n A175 L NOTICE Dry cleaning The dry cleaning does not have to be removed to dismantle the insulation Fig 39 Removing the insulation A175 L and smaller 1 Loosen and remove screws of insulation jackets...

Page 96: ...variant Fig 40 Dismantling the gas inlet casing A175 L and smaller screwed variant u If one of the screws 61009 shears off when loosening an ABB Turbocharging Service Station should be contacted 1 Lo...

Page 97: ...Systems Service Sta tion should be contacted u If a threaded stud 51086 works loose when removing the nut 51087 it should be refit ted after disassembling the gas outlet casing up to the stop in the...

Page 98: ...the nozzle ring A175 L Copyright 2020 ABB All rights reserved HZTL4034_EN Rev P January 2020 8 10 Dismantling the nozzle ring A175 L Fig 42 Dismantling the nozzle ring A175 L and smaller 1 Loosen scre...

Page 99: ...osening an ABB Turbocharging Service Station should be contacted 1 Dismantle both halves of the insulation segment 51215 and remove with all fixing ele ments 2 Detach flange connection between gas inl...

Page 100: ...when removing the nut 51087 it should be refit ted after disassembling the gas outlet casing up to the stop in the gas inlet casing until hand tight u If the nut 51087 cannot be removed with the maxim...

Page 101: ...le ring A180 L Copyright 2020 ABB All rights reserved HZTL4034_EN Rev P January 2020 8 12 Dismantling the nozzle ring A180 L Fig 45 Fitting the nozzle ring holder 1 Remove screws B2 2 Fit the nozzle r...

Page 102: ...nozzle ring 1 Loop around the nozzle ring holder 90477 with the lifting gear and secure it to the crane 2 Loosen screws 56014 and remove with washers 56011 3 Pull the nozzle ring 56001 towards the fr...

Page 103: ...L u Coat the screw threads with high temperature grease Fig 48 Fitting the nozzle ring A175 L and smaller Product Size Tightening torque Nm A165 L M10 35 A170 L M10 35 A175 L M10 35 Table 33 Tightenin...

Page 104: ...screwed variant Product Size Tightening torque Nm A165 L M16 301 140 A170 L M18 401 200 A175 L M22 501 380 Table 34 Tightening torque 61009 1 Pre tightening torque of the screws 1 Fit two guide studs...

Page 105: ...re tightening torque then to the tightening torque 7 Remove the lifting gear 8 Connect the flange of the gas inlet casing and the bellows 8 14 2 Variant with threaded stud Fig 50 Fitting the gas inlet...

Page 106: ...p posite positions 5 Coat remaining nuts with high temperature grease fit and then tighten crosswise ini tially to the pre tightening torque and then to the tightening torque 6 Remove the lifting gear...

Page 107: ...0 ABB All rights reserved HZTL4034_EN Rev P January 2020 8 16 Fitting the nozzle ring A180 L u Coat the screw threads with high temperature grease Fig 52 Looping around the nozzle ring A180 L and larg...

Page 108: ...M12 65 A185 L M12 65 A190 L M16 170 Table 36 Tightening torque 56014 1 Fit the nozzle ring holder 90477 on the flange of the gas inlet casing 51001 with screws B1 2 Remove screws B2 3 Align the notch...

Page 109: ...317 in the upper area on the gas outlet casing 61001 2 Loop around the gas inlet casing 51001 with the lifting gear and secure it to the crane 3 Dismantle and remove support 90451 from the gas inlet c...

Page 110: ...ase screw in up to the stop in the gas outlet casing 61001 and tighten hand tight 2 Loop around the gas inlet casing 51001 with the lifting gear and secure it to the crane 3 Dismantle and remove suppo...

Page 111: ...to protect against mechanical hazards CAUTION Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts u Have...

Page 112: ...Tightening torque Nm A165 L M5 6 A170 L M6 10 A175 L M8 25 A180 L M8 25 A185 L M10 45 A190 L M10 45 Table 40 Tightening torque 77015 1 Attach lifting gear L to the diffuser 79000 2 Carefully place th...

Page 113: ...d assembly 8 20 Fitting wall insert Copyright 2020 ABB All rights reserved HZTL4034_EN Rev P January 2020 8 20 Fitting wall insert Fig 58 Positioning wall insert u Carefully bring wall insert 77000 in...

Page 114: ...000 2 Fit two guide studs 90320 in the upper area of the compressor casing 72000 3 Align arrow markings of wall insert 77000 and compressor casing to one another 4 Carefully move the wall insert with...

Page 115: ...fer in terms of the fixing eyelets for the lifting gear The relevant vari ant must be taken into consideration for disassembly and assembly 8 21 2 Fitting the filter silencer welded If the turbocharge...

Page 116: ...the turbocharger is also fitted with a noise package chapter Fitting the filter silencer with noise package must be observed Fig 61 Fitting the filter silencer Product Size Tightening torque Nm A165...

Page 117: ...ed and cast versions of the filter silencer Before fitting ensure that the individual sealing segments of the gasket 81301 and the gas ket 74042 are not damaged and that the contact surfaces are clean...

Page 118: ...compressor cas ing 72000 2 Attach the lifting gear to the front lug and rear eyelet of the filter silencer 81000 paying attention to the version of the filter silencer 3 Position filter silencer on co...

Page 119: ...ration Manual 4 Product description A100 L 8 Disassembly and assembly 8 22 Fitting the filter silencer with noise package Copyright 2020 ABB All rights reserved HZTL4034_EN Rev P January 2020 Page 91...

Page 120: ...nd assembly 8 23 Table of tightening torques Copyright 2020 ABB All rights reserved HZTL4034_EN Rev P January 2020 8 23 Table of tightening torques Tightening torques Nm Fig 63 Overview of tightening...

Page 121: ...2300 63 1 72004 M14 130 M16 200 M18 300 M20 420 M22 570 M24 710 63a 72002 M14 40 M16 60 M18 80 M20 100 M22 120 M24 140 64 77015 M5 6 M6 10 M8 25 M8 25 M10 45 M10 45 65 56014 M10 35 M10 35 M10 35 M12...

Page 122: ...on the turbocharger is only permissible in emergencies It is not permitted to lock the rotor for an engine test Seri ous damage to engine or property can be caused by non compliance with the regulati...

Page 123: ...operation In order to ensure that the engine can continue operation as quickly as possible observe the following instructions 9 2 1 Procedure with one turbocharger installed per engine u Stop the eng...

Page 124: ...essive speeds The values provided by the enginebuilder apply to the max imum admissible engine load u Observe the permissible turbocharger speed for the unlocked turbochar ger u Reduce the engine load...

Page 125: ...l insert 77000 5 Align the hole circle of the locking device with the threaded holes in the compressor wheel 25000 6 Secure the locking device to the compressor wheel with the maximum possible number...

Page 126: ...001 to the gas outlet casing must be ensured In this case additional washers 01 must be provided in accordance with the following table These washers 01 are not supplied by ABB Fig 66 Ensuring clampin...

Page 127: ...rgers and joint air and ex haust gas receivers The cover plates for the compressor casing outlet gas inlet and gas outlet are not included in the ABB scope of delivery The following figure shows the p...

Page 128: ...anual 4 Product description A100 L 9 Taking a turbocharger out of operation 9 2 Taking defective tur bochargers out of operation Copyright 2020 ABB All rights reserved HZTL4034_EN Rev P January 2020 P...

Page 129: ...ing 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 c...

Page 130: ...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 131: ...piratory 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 regul...

Page 132: ...Turbocharging Service Station u If different model variants are not taken into account in this document contact an ABB Turbocharging Service Station The customer spare part sets 97070 97071 are avail...

Page 133: ...er spare part set 97071 Customer spare part set is required for service work on the turbocharger after 18 000 hours Quantity Designation Part number 1 O ring 77040 1 O ring 79020 1 O ring 79021 Table...

Page 134: ...A100 L 12 Spare parts 12 2 View of turbocharger with part numbers Copyright 2020 ABB All rights reserved HZTL4034_EN Rev P January 2020 12 2 View of turbocharger with part numbers Fig 68 View of turbo...

Page 135: ...exagon head screw 68002 Foot turbine end 72000 Compressor casing 72002 Threaded stud 72003 in the customer spare part set Washer 72004 in the customer spare part set Hexagon nut 72011 Hexagon head scr...

Page 136: ...ers Copyright 2020 ABB All rights reserved HZTL4034_EN Rev P January 2020 12 3 View of cartridge group with part numbers Fig 69 View of cartridge group with part numbers NOTICE Cartridge group The car...

Page 137: ...02 Radial bearing turbine end 32105 Floating disc 32106 Axial bearing 32109 Sealing disc 32159 Locking screw 32174 O ring 42001 Bearing casing 42008 Socket screw 42011 O ring 42015 Sealing cover 42039...

Page 138: ...the filter silencer 59 Fig 31 Dismantling the filter silencer 60 Fig 32 Dismantling the filter silencer with noise package 61 Fig 33 Pressing off compressor casing 62 Fig 34 Moving out wall insert 63...

Page 139: ...er 87 Fig 61 Fitting the filter silencer 88 Fig 62 Fitting the filter silencer with noise package 89 Fig 63 Overview of tightening torques 92 Fig 64 Tightening torques of speed sensor 92 Fig 65 Lockin...

Page 140: ...re too low 47 Table 22 Malfunctions during operation Charge air pressure too high 48 Table 23 Surging of the turbocharger 48 Table 24 Malfunctions when stopping Runout noises 49 Table 25 Malfunctions...

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