ABB A175-M66 Operating Manual Download Page 146

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Operation Manual / A170-M.. - A175-M..

Figures

HZTL4033_EN

Revision H

July 2021

Figures

Fig. 1: Serial number (01) on the rating plate ........... 4

Fig. 2: Layout and function........................................... 6

Fig. 3: Connection of the compressor wheel cooling ... 7

Fig. 4:

olatile

orrosion

nhibitor (VCI)................... 10

Fig. 5: Package with hygrometer................................ 11

Fig. 6: Warning plates on the turbocharger ............. 16

Fig. 7: Rating plate ........................................................ 17

Fig. 8: Locations of the rating plates ........................ 18

Fig. 9: Attachment of loads on the crane hook ....... 19

Fig. 10: Attachment angle............................................ 19

Fig. 11: Turbocharger suspension points ................ 28

Fig. 12: Turbocharger suspension points ................ 29

Fig. 13: Removing the foot mounting....................... 30

Fig. 14: Loosening the clamping nut ......................... 31

Fig. 15: Turbocharger suspension points ................. 32

Fig. 16: Removing auxiliary screw .............................. 33

Fig. 17: Compressor-end foot ..................................... 33

Fig. 18: Turbine-end foot ............................................ 34

Fig. 19: CE foot contact surface ................................ 35

Fig. 20: TE foot: Handling of cup spring contact sur-
face / foot contact surface ........................................ 35

Fig. 21: Tightening the foot screws (1)..................... 36

Fig. 22: Tightening procedure..................................... 37

Fig. 23: Lubricating oil pressure measuring point.. 41

Fig. 24: Speed measurement ..................................... 43

Fig. 25: Noise insulation, bellows .............................. 47

Fig. 26: Cleaning the filter silencer............................ 54

Fig. 27: Cleaning the filter silencer (2) ...................... 56

Fig. 28: Cleaning the slotted diffuser........................ 57

Fig. 29: Operation of water pressure vessel ........... 62

Fig. 30: Turbine and nozzle ring cleaning cycle ...... 66

Fig. 31: Cleaning cycle of turbine and nozzle ring
with load ramp.............................................................. 67

Fig. 32: Procedure Wet cleaning of turbine and
nozzle ring ....................................................................... 68

Fig. 33: Weight of assemblies ..................................... 78

Fig. 34: Removing the filter silencer .......................... 79

Fig. 35: Removing the air suction branch ................. 80

Fig. 36: Axial clearance.................................................. 81

Fig. 37: Removing wall insert ....................................... 82

Fig. 38: Transporting and turning wall insert .......... 83

Fig. 39: Removing the diffuser .................................... 84

Fig. 40: Removing the compressor casing ............... 85

Fig. 41: Safety-relevant screws ................................... 86

Fig. 42: Removing cartridge group 1.......................... 87

Fig. 43: Removing cartridge group 2 ......................... 88

Fig. 44: Removing turbine diffuser 1.......................... 89

Fig. 45: Removing turbine diffuser 2 ......................... 90

Fig. 46: Removing cover ring 1 .................................... 91

Fig. 47: Removing cover ring 2 .................................... 92

Fig. 48: Removing nozzle ring 1................................... 92

Fig. 49: Removing nozzle ring 2 .................................. 93

Fig. 50: Installing nozzle ring 1 .................................... 94

Fig. 51: Installing nozzle ring 2 .................................... 95

Fig. 52: Installing cover ring......................................... 96

Fig. 53: Installing turbine diffuser 1 ........................... 97

Fig. 54: Installing turbine diffuser 2........................... 98

Fig. 55: Installing the cartridge group 1 .................... 99

Fig. 56: Installing the cartridge group 2.................. 100

Fig. 57: Installing the cartridge group 3 .................. 100

Fig. 58: Preparing the threaded stud (25008) ....... 102

Fig. 59: Fitting the spinner nose cone (25012)....... 103

Fig. 60: Installing the compressor casing............... 104

Fig. 61: Installing diffuser........................................... 105

Fig. 62: Turning and moving in wall insert.............. 106

Fig. 63: Fitting wall insert........................................... 107

Fig. 64: Axial clearance ............................................... 108

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Summary of Contents for A175-M66

Page 1: ...ification Serial number HT607508 Customer part number Delivery date yyyy mm dd 2021 10 28 Weight 4600 kg Operating limits according to rating plate Speed limit in test rig operation only nMmax 316 1 s Speed limit during operation nBmax 302 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: ...ation on gas engines 15 2 7 Periodic check of the pressure vessels 15 2 8 Warning plates on the turbocharger 16 2 9 Turbocharger rating plate 17 2 10 Lifting of loads 19 2 11 Prerequisites for operation and maintenance 20 2 12 Hazards during operation and maintenance 21 2 13 Safe operation 23 2 14 Safe maintenance 24 3 Removal and installation 28 3 1 Turbocharger weight 28 3 2 Removing the turboch...

Page 4: ...ing 82 9 6 Removing the cartridge group 86 9 7 Removing the nozzle ring 89 9 8 Installing the nozzle ring 94 9 9 Installing the cartridge group 99 9 10 Fitting the spinner nose cone 102 9 11 Installing the compressor casing 104 9 12 Axial clearance A after assembly 108 9 13 Installing the air inlets 109 9 14 Removing and installing turbine end nozzle ring 112 9 15 Table of tightening torques 116 1...

Page 5: ... A170 M A175 M Table of contents Copyright 2021 ABB All rights reserved HZTL4033_EN Rev H July 2021 13 Spare parts 130 13 1 Ordering spare parts 130 13 2 Spare part Illustrations 132 14 Tools 142 Figures 144 Tables 146 ...

Page 6: ...plains the turbocharger and contains instructions for safe opera tion The Operation Manual is a complement to and expansion of existing national regulations for occupational safety accident prevention 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: ...is 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 ABB Turbocharging Service Station if you have any questions regarding a design variant see Contact information at www abb com turbocharging Accuracy of illustrations The illustrations in this document ar...

Page 8: ...ights reserved HZTL4033_EN Rev H July 2021 1 5 Layout and function of the turbocharger Fig 2 Layout and function 01 Filter silencer air suction branch 06 Gas inlet casing 02 Compressor wheel 07 Nozzle ring 03 Diffuser 08 Turbine 04 Bearing bush 09 Bearing casing 05 Gas outlet casing 10 Compressor casing Page 6 147 ...

Page 9: ...lubricating oil duct which is normally supplied by the lubric ating oil circuit of the engine The oil outlet is situated at the lowest point of the bearing casing 09 The compressor wheel 02 connected to the shaft draws in fresh air through the filter silen cer 01 or the air suction branch The air is compressed in the compressor and the down stream diffuser 03 and then led to the charge air cooler ...

Page 10: ...acilitates the work Definition of mandatory signs Mandatory signs show the protective equipment to be worn for a task The mandatory signs are described in chapter Safety and must be complied with Definition of Caution Warning Caution and warning signs are described in chapter Safety ABB Turbocharging ABB Switzerland Ltd Turbocharging is identified as ABB Turbocharging in this document Official ser...

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

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

Page 13: ...nspected 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 Turbocharging Service Station and repacked After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station Inspect the component Replace the desiccant agent Repackage the component NOTICE 70 fie...

Page 14: ...icient 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 ...

Page 15: ...ory mask to protect against Dusts Gases Safety helmet Ear protection Table 3 Personal protective equipment to be worn specific to the respective task 2 4 Definition of safety instructions WARNING 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 f...

Page 16: ... use of the turbocharger is limited to the specific application released at the time of de livery ABB accepts no liability and rejects all warranty claims for any non intended uses 1 Euromot The European Association of Internal Combustion Engine Manufacturers 2 Directive 94 9 EC concerning equipment and protective systems intended for use in po tentially explosive atmospheres ATEX The Euromot Posi...

Page 17: ...g deflagration event has taken place it is also recommended to check the bearings of the turbochargers before the next start An ABB Turbocharging Service Station should be instructed to carry out this inspection 2 7 Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging such as those for wet or dry cleaning are so called simple pressure vessels The locally applicable...

Page 18: ... 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 unreadable u Clean and degrease the areas designated for the warning plates u Fit new warning plates and remove protective sheets Turbochargers supplied to the enginebuilder without insulation must be equipped l...

Page 19: ... 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 h 04 Replacement interval of compressor in 1000 h 05 Replacement interval of turbine in 1000 h Further data 06 Customer part number 07 Designation for special design 08 Weight of turbocharger in kg 09 Turboc...

Page 20: ...st ABB Tur bocharging 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 replacement intervals increases the risk of unpredict able component failures Locations of the rat...

Page 21: ...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 22: ...ation Manual must be checked periodically Suitable working materials and personal protective equipment must be kept in a perfect condition Only authorised personnel may remain in the vicinity of the 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 Modif...

Page 23: ...ear 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 bur...

Page 24: ...viding protection against contact with hot surfaces u Compliance with the instructions and specifications given by the en ginebuilder to protect against hot turbocharger surfaces is compulsory Wear safety gloves to protect against thermal hazards Hazards due to rotating parts WARNING Hazards due to rotating parts Contact with rotating parts can cause severe injury The turbocharger is never allowed...

Page 25: ...d 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 operati...

Page 26: ...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 27: ... 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 vals...

Page 28: ...ns for which you have previously received instruc tion or training Hazards due to operating materials and supplies Operating materials and supplies are substances required for the operation of the tur 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 ma...

Page 29: ...he 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 combusti...

Page 30: ... limit must be used for removing 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 Turbocharger suspension points Product Weight of complete turbocharger unit kg A170 M 3100 A175 M 4600 Table 4 Weight of c...

Page 31: ...tion it may tip over and cause severe injury to per sonnel or accidents resulting in fatalities u Support the turbocharger at a suitable location u Secure with lifting gear wherever possible u If present Loosen cable to speed sensor u Disconnect all gas air and lubricating oil pipes Fig 12 Turbocharger suspension points u If present Remove insulation segments on bearing casing and feet u Attach li...

Page 32: ...reads of the threaded rods with penetrating oil and allow it to work in Do not oil the pressure screws of the clamping nut 2 Loosen the clamping nuts at the compressor end and turbine end foot see Loosening the clamping nut 31 3 Fit transport screws 90334 90335 to secure the sliding block 68003 on the left and right on the turbine end foot u Lift the turbocharger from the engine and put it down u ...

Page 33: ...ssure screws The pressure screws are equipped with a permanent sliding layer that must not be removed In case of non compliance it cannot be ensured that the necessary tension force is reached u Do not clean pressure screws u Do not lubricate pressure screws If a screw jams the previously loosened screw must be tightened again a little Fig 14 Loosening the clamping nut 1 Working in a circle break ...

Page 34: ...emoval and installation it may tip over and cause severe injury to per sonnel or accidents resulting in fatalities u Support the turbocharger at a suitable location u Secure with lifting gear wherever possible Fig 15 Turbocharger suspension points u If present Remove insulation segment on the bearing casing u Attach lifting gear to the suspension lug of the bearing casing and the turbine end foot ...

Page 35: ... of the foot and place in the toolbox The turbocharger is delivered with a pre installed sliding block 68003 The shipping screws secure the sliding block in the preset position In operation the foot can slip due to thermal expansion u Tighten clamping nuts as described in the following sections u Connect all gas air and oil pipes u If present Re fit the insulation segments u If present Connect cab...

Page 36: ...ension and strength class Product Dimension CE mm a1 b1 c1 A170 M 82 ø32x23 68 A175 M 95 ø38x31 85 Table 6 Foot screws dimension CE Product Dimension TE mm a2 a3 b2 c2 c3 A170 M 94 124 ø32x11 56 45 A175 M 113 148 ø38x12 66 54 Table 7 Foot screws dimension TE Product Number of cup springs X A170 M 9 A175 M 11 Table 8 Foot screws number of cup springs Holes b1 b2 are needed to achieve the required c...

Page 37: ...ighten clamping nuts on compressor end CE see Tightening the clamping nut 36 Fig 20 TE foot Handling of cup spring contact surface foot contact surface u Grease the contact surface F for the cup springs X see Table 5 Foot screws dimen sion and strength class 34 on the foot of the turbine end TE with high temperature grease u Tighten clamping nuts on turbine end TE see Tightening the clamping nut 3...

Page 38: ...cessary tension force is reached u Do not clean pressure screws u Do not lubricate pressure screws NOTICE Pressure screws d must not protrude from the clamping nut c in the dir ection of the thrust washer b In order to correctly fit the clamping nuts the pressure screws must not protrude in the direction of the thrust washer Fig 21 Tightening the foot screws 1 1 Clean the bolt thread a and the con...

Page 39: ...ightening 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 pr...

Page 40: ...s specifications regarding the selection of lubricating oil and the oil change intervals For more information on the oil supply refer to Chapter Oil pressure oil temperature 41 4 1 2 Pre lubrication and post lubrication The pre lubrication time is at least 2 minutes The post lubrication time is 10 minutes If the engine is operated in idle mode 10 minutes before stopping no additional post lubric a...

Page 41: ... Serious damage to engine or property can be caused by dirt and solid ma terial particles in the oil u For the initial commissioning phase and after all service work flush the complete lubricating system with warm oil u Use special running in filters when running in the engine and after all ser vice work on the lubricating system u Check that the oil filter is clean before commissioning u Check th...

Page 42: ...an liquefy or vaporise and escape as oily fluids during the initial hours of operation Continual escape of an oily fluid indicates an oil leak u If there is a leak contact an ABB Turbocharging Service Station 4 3 Commissioning after taking out of operation If present u Remove cover plates blind flanges from the compressor casing the gas inlet and the gas outlet General u Check the exhaust gas pipe...

Page 43: ...toring the lubricating oil pressure ABB Turbocharging recommends installing a manometer M If the pressure is controlled electronically the relevant signals should be triggered at the warning and alarm values Fig 23 Lubricating oil pressure measuring point The permitted oil pressure ranges at measuring point M of the turbocharger are listed be low Status for operation Pressure at measuring point M ...

Page 44: ...tlet 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 monitored according...

Page 45: ...r speeds CAUTION Do not put the speed 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 2 2 Layout and overview Fig 24 Speed measurement 86505 Speed sensor 86506 O ring 86515 Cable connector 86526 F I converter 86528 Tachometer 42047 Screw plug 32118 Auxiliary bearin...

Page 46: ... the maximum tur bocharger speed does not exceed 70 of nBmax u If the engine cannot be stopped it can continue to be driven at this reduced engine load or turbocharger speed u If a turbocharger surges continuously the engine performance must be reduced further u Measure the temperatures in the air lines and gas piping from and to the turbochargers and compare with normal values If clear deviations...

Page 47: ...idling and then stop the engine Pay attention to post lubrication Stopping the engine 52 u Switch off the lubricating oil supply to the turbocharger u Disconnect the cable connector from the speed sensor u Screw out defective speed sensor u Screw in new speed sensor to the stop The speed sensor is designed with a sealing lip and does not require any additional gasket for assembly u Connect cable c...

Page 48: ...f 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 eng...

Page 49: ...021 ABB All rights reserved HZTL4033_EN Rev H July 2021 Suggestion for noise insulation bellows Fig 25 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 47 147 ...

Page 50: ...ions can lead to untimely machine damage even if the prescribed service intervals are ob served u Agree on a specific service interval with ABB Turbocharging To prevent machine damage caused by ageing and downtime we recommend having an in spection carried out by an ABB Turbocharging Service Station no later than 5 years after the last service 6 2 1 Service work every 25 50 hours u Visual check fo...

Page 51: ...Balancing rotor 6 2 4 Service work every 24000 36000 hours of operation Service work on the rotor and bearing parts must be carried out by an ABB Turbocharging Service Station Damaged and worn out parts must be replaced with original ABB parts u Disassemble the turbocharger u Clearance measurement u Clean turbine casing and compressor casing and check for cracks and erosion corrosion u Clean beari...

Page 52: ... 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 gas temperature before and after the turbine Pressure of the charge air Pressure loss in the charge air cooler Lubricating oil pressure and lubricating oil temperature If present Air temperature after...

Page 53: ...nts exposed to hot gas A decisive role is played by various influencing parameters which in extreme cases can drastically reduce the replacement interval of these parts During the prescribed periodic service work the individual parts are examined for wear and replaced if necessary Influencing parameters for bearing parts Inferior lubricating oil quality lubricating oil filtering lubricating oil co...

Page 54: ...000 50000 Other casings 100000 100000 Turbine blades due to wear 12000 Table 13 Expected replacement intervals GAS Gas MDO Marine Diesel Oil HFO Heavy Fuel Oil Recommended replacement intervals h Rotor components See information on rating plate Bearings See information on rating plate Table 14 Recommended replacement intervals 6 4 Stopping the engine CAUTION Stopping the engine In the turbocharger...

Page 55: ...033_EN Rev H July 2021 7 Periodic maintenance 7 1 Foreword to maintenance Maintenance work includes regular visual controls and cleaning operations which are inten ded to ensure the trouble free functioning of the turbocharger Described maintenance points Filter silencer Diffuser Compressor Turbine and nozzle ring Page 53 147 ...

Page 56: ...ering Cleaning the filter ring if present u Remove filter ring 81265 u Clean filter ring 81265 as required or every 500 hours of operation and replace after the fifth cleaning process at the latest The contamination of the filter ring depends on the degree of purity of the sucked in air u Rinse the filter ring 81265 with water and mild detergent or in the case of heavy con tamination soak and care...

Page 57: ... an ABB Turbocharging Service Station Fitting the cover grids and absorption segments see Fig 26 Cleaning the filter silencer 54 CAUTION Penetration of dirt and foreign particles Any penetration of dirt and foreign particles into the compressor can dam age it u Fit the connecting rods 81269 correctly in the slots on the filter silencer body 81135 u It must not be possible to rotate or move the cov...

Page 58: ...e screws 81272 While tightening the screws 81272 make sure that the connecting rods 81269 lie correctly in the slots on the filter silencer body 81135 Now alternately tighten the screws 81272 up to the following maximum tightening torque Screw Tightening torque Nm 81272 20 Table 15 Tightening torque 81272 u Fit lock nuts 81273 on screws 81272 and tighten with the following tightening torque Lock n...

Page 59: ...tted diffuser u Remove the diffuser see Removing the compressor casing 82 Fig 28 Cleaning the slotted diffuser u Clean the diffuser slots S When cleaning please note that this should only take place using lightly pressurized air a brush and a moist cleaning cloth u Have any heavily contaminated or damaged diffusers replaced by an ABB Turbocharging Service Station Page 57 147 ...

Page 60: ...m in the flow channels if salt oil mist or dust are sucked in with the air Consequences of contamination Impaired compressor efficiency Higher exhaust gas temperatures Increased fuel consumption Increased 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 turbocharger i...

Page 61: ...t The coating is removed by the mechanical action of the impacting droplets The process is particularly suitable as long as the contamination is not too advanced 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 CAUTION Volume of water Uncontrolled vol...

Page 62: ...be in creased u No personnel is allowed to be present in the vicinity of the turbocharger during compressor cleaning u Compressor cleaning must be activated from the engine control panel Wet cleaning operations for compressor with direct water supply u Trigger water injection according to the specifications of the enginebuilder u Observe specified water pressure upstream of the connection to the t...

Page 63: ...sed pressure loss in the charge air cooler and corrected if necessary If surging of the compressor stage continues to occur during compressor cleaning despite correct settings this can be remedied by reducing the engine load further during cleaning of the compressor The reduction of the engine load can lead to a reduction in the effective ness of the compressor cleaning u To avoid a reduction in e...

Page 64: ...commended by ABB Turbocharging the following prerequisites must be fulfilled Engine load 50 85 u Start the cleaning operation according to the following description Operation of compressor wet cleaning Fig 29 Operation of water pressure vessel Operation of the water pressure vessel u The prerequisites for operating state for cleaning the compressor with XC3 must be ful filled before the cleaning u...

Page 65: ...ng of the compressor stage occur during compressor cleaning first the cleaning parameters water flow rate as well as the engine side system must be checked with regard to deviations e g an increased pressure loss in the charge air cooler and corrected if necessary If surging of the compressor stage continues to occur during compressor cleaning despite correct settings this can be remedied by reduc...

Page 66: ...onents ABB Turbocharging recommends the use of fuels with low ash sulphur sodium and vana dium contents Consequences of contamination Low turbine efficiency Elevated exhaust gas temperatures Increased charging and ignition pressures with increasing turbocharger speed Lower engine performance Rotor sticking after stopping the engine Periodic cleaning of the turbine during operation prevents or dela...

Page 67: ...sely affect turbocharger parts u Never use salt water but only pure water for cleaning The influence of the cleaning water on the peripheral units such as the boiler must be clari fied by the operator before commencing wet cleaning The turbine end components are cleaned at reduced engine load The exhaust gas temperat ure must not exceed the value specified in the cleaning instructions see section ...

Page 68: ...ing prerequisites have been tested and ap proved by ABB Turbocharging for cleaning operations u Set the engine load between 20 50 so that the turbine inlet temperature is between 380 430 C Fig 30 Turbine and nozzle ring cleaning cycle u Once the turbine inlet temperature is stable and has dropped below 430 C wait at least another 10 minutes to allow the turbine end turbocharger parts to cool down ...

Page 69: ...ow MTurb 4 1 kg s Turbine pressure ratio PIT 1 1 Turbine inlet temperature between 380 430 C Fig 31 Cleaning cycle of turbine and nozzle ring with load ramp u As soon as the turbine inlet temperature is stable and less than 430 C wait for least 10 additional minutes for the turbine end turbocharger components to cool down u Start the cleaning cycle according to the following description Wet cleani...

Page 70: ...rs Wet cleaning of turbine and nozzle ring 69 If there is insufficient water pressure the water flow rate specified in the table will not be achieved A reduced cleaning effect can be expected in this case Repetition of wet cleaning The repeating of cleaning cycles one immediately after the other must be avoided as this can lead to excessive mechanical stress hence reducing the operating life of th...

Page 71: ...speed or a very large increase in the gas inlet temperature In such cases the cleaning operations must be stopped and the cleaning cycle restarted with re duced water pressure or higher engine load Cleaning parameters for wet cleaning of turbine and nozzle ring Product Maximum temperature when starting cleaning TTI C Injection time t i min Water volume flow per turbocharger1 VW dm min A170 M 430 1...

Page 72: ...on Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Contact enginebuilder Table 21 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 o...

Page 73: ... filter heavily contaminated Clean Oil pump in lubricating system defect ive Check replace Manometer displays incorrectly Replace manometer Table 23 Malfunctions during operation Lubricating oil pressure too low Drop in speed Possible causes Remedy Turbochar ger Heavy contamination of the turbine and or nozzle ring Clean see chapter Periodic mainten ance 53 Damaged rotor components or bearing Cont...

Page 74: ... clean cooling system Insufficient ventilation Improve ventilation Table 26 Malfunctions during operation Exhaust gas temperature too high Charge air pressure too low Engine performance and engine speed unchanged suction condition normal Possible causes Remedy Turbochar ger Manometer display not correct Replace manometer Supply pipe to manometer not sealed Repair leak Filter silencer contaminated ...

Page 75: ... of the turbocharger CAUTION Continuous or periodic surging If the turbocharger surges continuously or periodically parts of the tur bocharger may be damaged u Gradually reduce the engine load u Have the cause clarified and remedied immediately by an ABB Turbochar ging Service Station u Have parts assessed for damage and if necessary replaced by an ABB Turbocharging Service Station Surging of the ...

Page 76: ... turbocharger A surge blow is accompanied by a loud bang and escape of hot air from the filter silencer 8 4 Malfunctions when stopping Runout noises Possible causes Remedy Turbochar ger Turbocharger contaminated Clean Bearing damaged Contact an ABB Turbocharging Service Station Rotor rubbing Foreign object in the turbocharger Table 30 Malfunctions when stopping Runout noises Shortened runout time ...

Page 77: ...vice Station Table 32 Malfunction No speed measurement 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 and hence to false triggering For information regardi...

Page 78: ... set is available see chapter Tools 142 Not all tools are marked with a part number Identification is guaranteed by the tool list This list is enclosed with the tool set WARNING Servicing the 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 Customer spare part set...

Page 79: ...ook 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 and designed...

Page 80: ... are rounded up standard values Fig 33 Weight of assemblies Position Component A170 M kg A175 M kg 01 Filter silencer 260 400 02 Radial air suction branch 120 170 03 Wall insert 210 320 04 Diffuser 30 45 05 Compressor casing 430 620 06 Cartridge group 750 1100 07 Turbine diffuser 80 130 08 Cover ring 40 60 09 Nozzle ring 17 25 10 Gas inlet casing radial 170 230 11 Gas inlet casing axial 115 170 Ta...

Page 81: ...3 Removing the air inlets 9 3 1 Removing the filter silencer u Dismantle insulation as far as necessary Fig 34 Removing the filter silencer 1 Loop lifting gear through the fin on the filter silencer and secure to the eyelets at the rear with shackles 90195 2 Loosen nuts 72027 and remove with washers 72028 u Remove and put down filter silencer Page 79 147 ...

Page 82: ...9 3 2 Removing the air suction branch u Disconnect all air lines according to the instructions of the enginebuilder u Dismantle insulation as far as necessary Fig 35 Removing the air suction branch 1 Loop lifting gear around air suction branch 2 Loosen and remove the nuts 72027 with washers 72028 u Remove and put down the air suction branch Page 80 147 ...

Page 83: ...afety gloves to protect against mechanical hazards The axial clearance A must be measured prior to removal and after installation of the cart ridge group CAUTION Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts u Have the components assessed and if necessary replaced by an ABB Tur bocharging Service ...

Page 84: ...wall insert screw in one screw 72011 a third of the way 3 Press off wall insert with three screws 72011 until the lifting device 90190 and the fix ing segment 90192 can be fitted 4 Fit the lifting device 90190 and the fixing segment 90192 to the flange of the wall in sert 77000 using the screws 90197 and washers 90198 Depending on the hole pattern of the wall insert 77000 the screws 90197 cannot b...

Page 85: ...033_EN Rev H July 2021 7 Pull out wall insert 77000 Transporting and turning wall insert Fig 38 Transporting and turning wall insert 1 Fit support angle 90025 with bolts and nuts 2 Carefully turn wall insert over support angle 90025 and place on supports u Place wall insert such that lifting device 90190 90195 can be removed Page 83 147 ...

Page 86: ...pressor casing Copyright 2021 ABB All rights reserved HZTL4033_EN Rev H July 2021 Removing the diffuser Fig 39 Removing the diffuser 1 Remove and dispose of the O ring 77040 2 Loosen and remove screws 77015 3 Loop lifting gear around diffuser 79000 and remove diffuser Page 84 147 ...

Page 87: ...021 Removing the compressor casing Fig 40 Removing the compressor casing 1 Using screws 90196 and washers 90198 fasten lifting device 90190 90195 to com pressor casing 72000 and secure to crane 2 Loosen and remove nuts 61037 3 Use press off nuts 61090 to fully press off and remove compressor casing 72000 4 Remove and dispose of the O ring 42012 Page 85 147 ...

Page 88: ...AUTION Oil orifices There is an orifice for adjusting the oil pressure in each of the two oil supply pipes of the bearing casing When the cartridge group the bearing casing or the turbocharger is being fitted to the engine it must be ensured that the orifices specified for the turbocharger are installed in both oil supply pipes u Check that the oil orifices have been correctly installed Version wi...

Page 89: ...ing cartridge group 1 1 Unplug cable connector 86515 and unscrew speed sensor 86505 with O ring 86506 Dispose of the O Ring 86506 2 Loosen socket screw 25013 and remove washer 25014 3 Press off the spinner nose cone 25012 using the press off screw 90917 4 Loosen and remove the screw 61059 5 Loosen and remove nuts 42128 6 Attach lifting gear to bearing casing Page 87 147 ...

Page 90: ...ne diffuser during disas sembly assembly by rotating the rotor Fig 43 Removing cartridge group 2 1 Only for A170 M 1 Evenly press off cartridge group by screwing three press off screws 90900 into the designated holes 2 A170 M Using two guide studs 90490 and adapter 90199 move out the cartridge group A175 M Using two guide studs 90490 move out the cartridge group 3 Fit supports 90450 and put down c...

Page 91: ...off screw 90915 for pressing off the turbine dif fuser with thread size M18x1 0 can easily be mixed up with the press off screw 90901 with thread size M18x1 5 If the press off screws are mixed up the thread of the turbine diffuser can be damaged u Always use the appropriate press off screws Fig 44 Removing turbine diffuser 1 1 Remove screws 61069 2 Using press off screws 90915 press off turbine di...

Page 92: ...ights reserved HZTL4033_EN Rev H July 2021 Fig 45 Removing turbine diffuser 2 5 Pull turbine diffuser 63000 out as far as it will go at guide plates 6 Loop around turbine diffuser and secure to lifting gear 7 Remove nuts 61037 and guide plates 90328 8 Completely pull out and put down turbine diffuser Page 90 147 ...

Page 93: ...033_EN Rev H July 2021 Removing cover ring Fig 46 Removing cover ring 1 1 Refit guide plates 90328 with nuts 61037 2 Loosen and remove 57005 bolts Press off cover ring with the press off screws 90916 for A170 M or 90901 for A175 M in the provided holes 3 Pull cover ring 57001 out as far as it will go at the guide plates Page 91 147 ...

Page 94: ...d cover ring and secure to lifting gear 5 Remove guide plates 90328 and nuts 61037 6 Fully pull out and put down cover ring 57001 Removing the nozzle ring Fig 48 Removing nozzle ring 1 1 Bend open locking washers 56015 loosen and remove screws 56014 2 Secure retaining plate 90338 with screws 90339 and hook guide rod 90336 into re taining plate 3 Fit guide plate 90328 with nuts 61037 Page 92 147 ...

Page 95: ...r as it will go at guide plate 5 Loop around nozzle ring 56001 and secure to lifting gear 6 Remove guide plate 90328 and nuts 61037 7 Fully pull out and put down nozzle ring 56001 Blocked areas on nozzle ring If a nozzle ring is blocked in some areas or is covered by loose parts it is recommended to appoint an ABB Turbocharging Service Station to inspect the turbine blades and carry out a crack in...

Page 96: ...alling the nozzle ring Fig 50 Installing nozzle ring 1 1 Secure retaining plate 90338 with screws 90339 and hook in guide rod 90336 2 Using lifting gear position nozzle ring 56001 on guide rod 90336 Do not take strain off lifting gear yet 3 Fit guide plate 90328 with nuts 61037 4 Remove the lifting gear 5 Position nozzle ring 56001 in gas outlet casing Page 94 147 ...

Page 97: ... M M10 50 Table 37 Tightening torque 56014 6 Loosen nuts 61037 and remove guide plate 90328 7 Loosen screws 90339 and remove retaining plate 90338 with guide rod 90336 8 Coat the threads of screws 56014 and the contact surface between screw and locking washer with high temperature grease 9 Fit the nozzle ring 56001 on the gas inlet casing 51001 using the screws 56014 and locking washers 56015 10 B...

Page 98: ... M M16 200 Table 38 Tightening torque 57005 1 Using lifting gear move in cover ring 57001 over guide studs 90802 with notch V fa cing the gas outlet flange until the lifting gear is on the gas outlet casing 2 Fit guide plates 90328 with nuts 61037 3 Remove the lifting gear 4 Slide in cover ring as far as it will go 5 Remove guide plates 90328 and nuts 61037 6 Coat threads of screws 57005 with high...

Page 99: ...turbine diffuser Fig 53 Installing turbine diffuser 1 1 Using lifting gear move turbine diffuser 63000 in over guide studs 90802 until the lifting gear is on the gas outlet casing 2 Fit guide plates 90328 with nuts 61037 3 Remove the lifting gear 4 Slide in turbine diffuser as far as it will go 5 Remove nuts 61037 guide plates 90328 and guide studs 90802 Page 97 147 ...

Page 100: ...ght 2021 ABB All rights reserved HZTL4033_EN Rev H July 2021 Fig 54 Installing turbine diffuser 2 Product Size Tightening torque Nm A170 M M14 130 A175 M M16 200 Table 39 Tightening torque 61069 6 Coat threads of screws 61069 with high temperature grease 7 Fit and tighten screws 61069 Page 98 147 ...

Page 101: ...f the blade tips on the casing u Check that the blades do not rub on the turbine diffuser during disas sembly assembly by rotating the rotor Fig 55 Installing the cartridge group 1 1 Only for A170 M 1 Fasten lifting gear to bearing casing and lift cartridge group slightly 2 Remove support 90450 3 A170 M Using two guide studs 90490 and adapter 90199 carefully move in cartridge group A175 M Using tw...

Page 102: ...56 Installing the cartridge group 2 Product Size Tightening torque Nm A170 M M22 400 A175 M M24 490 Table 40 Tightening torque 61059 42128 1 Coat thread of screw 61059 and two bolts for the nuts 42128 with high temperature grease 2 Secure cartridge group with screw 61059 and nuts 42128 3 Remove the lifting gear Fig 57 Installing the cartridge group 3 Page 100 147 ...

Page 103: ...s There is an orifice for adjusting the oil pressure in each of the two oil supply pipes of the bearing casing When the cartridge group the bearing casing or the turbocharger is being fitted to the engine it must be ensured that the orifices specified for the turbocharger are installed in both oil supply pipes u Check that the oil orifices have been correctly installed u Remove temporary covers on...

Page 104: ...ted correctly or the socket screw 25013 is not correctly tightened the spinner nose cone can work loose dur ing operation and cause total failure of the turbocharger u Follow the assembly instructions u Always use a new socket screw 25013 and washer 25014 from the cus tomer spare part set 97070 u Only use new Loctite 542 supplied by the ABB service station u Observe and note down control dimension...

Page 105: ...que 25013 Always use a new socket screw 25013 and washer 25014 from the customer spare part set 97070 5 Fit the spinner nose cone and secure with washer 25014 and socket screw 25013 Ob serve tightening torque The following must be taken into account u The tightening torque must be applied by two people One person tightens socket screw 25013 while the second person holds the compressor wheel 25000 ...

Page 106: ...00 A175 M M24 490 Table 44 Tightening torque 61037 Product Pre tightening torque Nm Tightening angle A170 M 30 45 5 A175 M 40 45 5 Table 45 Tightening torque nuts that are difficult to access 61037 Product Size Tightening torque Nm A170 M M22 50 A175 M M24 50 Table 46 Tightening torque 61090 1 Distributed evenly around the circumference screw the press off nuts 61090 onto the studs of the bearing ...

Page 107: ...sing 72000 Tighten nuts 61037 crosswise 5 Remove lifting device 90190 90195 6 Tighten the three press off nuts 61090 against compressor casing 72000 by applying the corresponding tightening torque Installing diffuser Fig 61 Installing diffuser Product Size Tightening torque Nm A170 M M5 6 A175 M M6 10 Table 47 Tightening torque 77015 1 Loop around diffuser 79000 with lifting gear and position it o...

Page 108: ...ert 1 Secure the lifting device 90190 90195 and the fixing segment 90192 to the flange of the wall insert 77000 using the screws 90197 and washers 90198 Carefully turn wall insert 77000 with fitted diffuser over the support angle 90025 and pull up vertically 2 Remove support angle 90025 screws and nuts 3 Carefully install the wall insert 77000 in the compressor casing Make sure both mark ings are ...

Page 109: ...Product Size Pre tightening torque Nm Tightening angle A170 M M20 230 30 5 A175 M M24 350 30 5 Table 48 Tightening torque 72011 1 Remove lifting device 90190 90195 and fixing segment 90192 2 Push the wall insert 77000 into the compressor casing as far as it will go 3 Secure wall insert with screws 72011 and washers 72008 For assembly of the alternative air inlet see section Installing air inlets P...

Page 110: ...gloves to protect against mechanical hazards The axial clearance A must be measured prior to removal and after installation of the cart ridge group CAUTION Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts u Have the components assessed and if necessary replaced by an ABB Tur bocharging Service Statio...

Page 111: ...on branch Fig 65 Installing the air suction branch Product Size Tightening torque Nm A175 M M20 220 A170 M M18 170 Table 50 Tightening torque 72027 1 Loop lifting gear around air suction branch 2 Fit air suction branch together with nuts 72027 and washer 72028 Observe tightening torque u Disconnect all air lines according to the instructions of the enginebuilder u Dismantle insulation as far as ne...

Page 112: ...filter silencer Product Size Tightening torque Nm A170 M M18 170 A175 M M20 220 Table 51 Tightening torque 72027 1 Loop lifting gear through the fin on the filter silencer and secure to the eyelets at the rear with shackles 90195 2 Fit filter silencer together with nuts 72027 and washers 72028 Observe tightening torque Tighten nuts that are difficult to access with a fork ring spanner u Fit insula...

Page 114: ...ons Spiral wound gaskets may only be used once u Provide new spiral wound gasket 61050 NOTICE Blocked areas on nozzle ring If a nozzle ring is blocked in some areas or is covered by loose parts it is re commended to appoint an ABB Turbocharging Service Station to inspect the turbine blades and carry out a crack inspection In order to access the fixing screws and loop around and transport the gas i...

Page 115: ... inlet casing Fig 68 Removing the nozzle ring at the turbine end axial gas inlet casing 1 If present Remove connecting pipe for turbine cleaning 2 Loop around gas inlet casing 51001 and secure with lifting gear 3 Loosen screws 61009 and move out gas inlet casing with nozzle ring 4 Bend open locking washers 56015 loosen and remove screws 56014 5 Pull out nozzle ring 56001 6 Remove spiral wound gask...

Page 116: ...ng turbine end nozzle ring Copyright 2021 ABB All rights reserved HZTL4033_EN Rev H July 2021 Installing the nozzle ring Fig 69 Installing the nozzle ring at the turbine end radial gas inlet casing Fig 70 Installing the nozzle ring at the turbine end axial gas inlet casing Page 114 147 ...

Page 117: ... the screws 56014 and new locking washers 56015 Bend over locking washers 2 Fix new spiral wound gasket 61050 in groove of gas outlet casing 61001 at three evenly distributed points with a little superglue such as Loctite 454 3 Fit two guide studs 90321 in the upper part of the gas outlet casing 61001 4 Coat threads of screws 61009 with high temperature grease 5 Loop around gas inlet casing 51001 ...

Page 118: ...M 9 Disassembly and assembly 9 15 Table of tightening torques Copyright 2021 ABB All rights reserved HZTL4033_EN Rev H July 2021 9 15 Table of tightening torques Fig 71 Tightening torques 1 Fig 72 Tightening torques 2 Page 116 147 ...

Page 119: ...4 490 05 61090 M22 50 M24 50 06 61059 42128 M22 400 M24 490 07 61069 M14 130 M16 200 08 63001 M14 170 M18 240 09 56014 M10 50 M10 50 10 61009 M18 2801 M20 3801 11 57005 M14 130 M16 200 12 42059 M16 200 M16 200 13 72011 M20 2302 30 5 3 M24 3502 30 5 3 14 72027 M18 170 M20 220 15 72026 M18 40 M20 50 16 25013 M8 20 M10 40 17 86505 M18x1 5 150 M18x1 5 150 Table 54 Tightening torques 1 Tighten screws 6...

Page 120: ...s Copyright 2021 ABB All rights reserved HZTL4033_EN Rev H July 2021 Tightening sequence Fig 73 Flange tightening sequence Product Tightening torque 61009 Nm Step 1 Step 2 Step 3 Step 4 A170 M hand tight 80 170 280 A175 M hand tight 100 240 380 Table 55 Tightening torques 61009 Page 118 147 ...

Page 121: ...er locking the turbocharger contact an ABB Turbocharging Service Station and find the nearest port u Observe the safety regulations u Follow the directives of the enginebuilder WARNING Danger of fire and explosion due to lubricating oil leaks Leaking oil may ignite on hot surfaces This can result in serious injuries to personnel or fatal accidents u Cordon off danger area u Raise the alarm and dep...

Page 122: ...r u If there is a lubricating oil leak on the turbocharger stop the oil supply A locked rotor must be removed after emergency operation and checked for unbalance see chapter Removing the cartridge group The unbalance check must be carried out by an ABB Turbocharging Service Station Exception The exception concerns customer requirements for test bed runs of new engines at a max imum engine load of ...

Page 123: ...duct Part number 72011 Part number 94006 94007 A170 M 170 Nm 25 Nm A175 M 220 Nm 50 Nm Table 56 Locking device tightening torque 1 Press off the spinner nose cone 25012 with the press off screw 90917 2 Remove two studs 72026 and three screws 72011 in the upper area 3 Insert the lifting spigot 90441 into the compressor wheel Screw screws 94007 into the free threaded holes of the compressor wheel 4 ...

Page 124: ...the speeds of the undamaged turbochargers u Reduce the engine load if necessary If the engine is equipped with a common air receiver and separate exhaust gas receivers the bellows on the compressor outlet of the damaged turbocharger must always be removed and the air line on the engine side must be blanked off Otherwise the undamaged tur bocharger can spin empty without load and run at overspeed D...

Page 125: ...nufactured according to the drawing from the oper ator Fig 75 Cover plate 01 spacer sleeves 02 dimensions Cover plate 01 spacer sleeves 02 dimensions mm Product B1 B2 B3 B4 B5 B6 B7 B8 A170 M 13 432 50 50 9 12 8 96 A175 M 13 500 50 50 9 12 8 112 Table 57 Cover plate dimensions 1 Product Ø 1 Ø 2 Ø 3 Ø 4 Ø 5 Ø 6 A170 M 835 915 872 4 24 34 20 A175 M 965 1050 1007 5 26 36 20 Table 58 Cover plate dimen...

Page 126: ...nuts 61037 u Close the lubricating oil supply to the turbocharger 10 3 1 Further measures and information for the operation of 4 stroke engines with a cover plate of the turbocharger 4 stroke engine with a turbocharger No further measures are necessary The engine can be operated as a suction engine accord ing to the instructions of the enginebuilder 4 stroke engine with several turbochargers Separ...

Page 127: ...chargers build up a receiver pressure 10 4 Blanking off the inlets and outlets The chapter is only applicable for engines with several turbochargers and joint air and ex haust gas receivers u Close the lubricating oil supply to the turbocharger u Blank off flange from compressor casing outlet gas inlet and gas outlet by the installa tion of cover plates u Observe specifications from enginebuilder ...

Page 128: ...rosion Preparations for mothballing WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or con tact with them may be harmful to health u Do not breathe in these substances and avoid contact with the skin u Ensure proper ventilation u Observe the information in the material safety data sheet for the operat ing materials and supplies u...

Page 129: ...Service Station and stored separately The turbocharger is completely removed either as a whole unit or in individual parts For the measures always necessary for 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 ou...

Page 130: ... 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 ABB Switzerland Ltd Turbocharging do not fall within the Scope of RoHS2 due to their appl...

Page 131: ... 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 fe...

Page 132: ...hen making queries and ordering spare parts Turbocharger type Serial number of the turbocharger Designation and part number Spare parts can be ordered from any ABB Turbocharging Service Station u If different model variants are not taken into account in this document contact an ABB Turbocharging Service Station u Dispose of placed and unusable parts in an environmentally friendly and professional ...

Page 133: ...e quired These parts are only available in the complete set Customer spare part set 97070 Designation Quantity 25013 Socket screw 1 25014 Washer 1 42012 O ring 1 42041 Gasket 1 42045 Gasket 2 42059 42064 Hexagon head screw 2 56014 Hexagon head screw 2 56015 Locking washer 2 57005 Hexagon head screw 5 61037 Hexagon nut 3 61069 Hexagon head screw 3 77015 Socket screw 3 77040 O ring 1 86506 O ring sp...

Page 134: ...9 42040 42058 42041 42064 42063 42044 10900 42009 42170 25012 42012 25014 25013 Available within the spare part set Part no Designation 10900 Cartridge 25012 Spinner nose cone 25013 Socket screw 25014 Washer 42009 Screw plug 42012 O ring 42040 Oil outlet flange 42041 Gasket 42044 Flange 42045 Gasket 42058 Verbusripp washer 42059 Hexagon head screw 42063 Verbusripp washer 42064 Hexagon head screw 4...

Page 135: ...15 42011 42400 42049 42043 42306 42099 42001 42305 42300 42008 Available within the spare part set Part no Designation 42001 Bearing casing 42008 Socket screw 42011 O ring 42015 Sealing cover 42016 Screw 42043 Orifice 42049 Locking ring 42099 Socket screw 42300 Partition wall 42305 O ring 42306 O ring 42400 Heat shield Table 62 Spare parts Bearing casing Page 133 147 ...

Page 136: ...nly without spinner nose cone Part no Designation 21000 Turbine 21001 Turbine unbladed 21005 Locking plate 21010 Labyrinth sleeve 25000 Compressor wheel 25008 Threaded stud 25009 Ring nut 25011 O Ring 29000 Turbine blade 32001 Thrust bearing 32003 O ring 32101 Radial bearing compressor end 32102 Radial bearing turbine end 32105 Floating disc 32106 Axial bearing 32107 Bearing bush 32118 Auxiliary b...

Page 137: ...arts 13 2 Spare part Illustrations Copyright 2021 ABB All rights reserved HZTL4033_EN Rev H July 2021 Water vessel 27000 27005 p p pre assembled Part no Designation 27000 Water vessel 27005 p Plug Table 64 Spare parts Water vessel Page 135 147 ...

Page 138: ...1169 56014 51001 51074 56001 52208 51258 51256 51259 56015 Available within the spare part set Part no Designation 51001 Gas inlet casing 51074 Screw plug 51169 Screw plug 51256 Union nut 51258 Pressure plate 51259 Hexalobular head screw 52208 Nozzle 56001 Nozzle ring 56014 Hexagon head screw 56015 Locking disc Table 65 Spare parts Gas inlet casing axial Page 136 147 ...

Page 139: ... radial Cleaning device 51064 51077 51062 51169 51078 51001 56001 56015 56014 Available within the spare part set Part no Designation 51001 Gas inlet casing 51062 Verbusripp washer 51064 Screw 51077 Blind flange 51078 Gasket 51169 Screw plug 56001 Nozzle ring 56014 Hexagon head screw 56015 Locking disc Table 66 Spare parts Gas inlet casing radial Page 137 147 ...

Page 140: ...321 51322 51329 51328 51255 51257 51318 51323 51325 51324 51327 Part no Designation 51255 Locking plate 51257 Sleeve 51318 Water connection 51319 Blind flange 51320 Hexagon head screw 51321 Hexagon nut 51322 Hexagon head screw 51323 Gasket 51324 Flange 51325 Union bush 51327 Pipe 51328 Hexagon socket head pipe 51329 Gasket Table 67 Spare parts Cleaning device for gas inlet casing Page 138 147 ...

Page 141: ...2006 72005 72026 77040 72028 72027 72060 77000 72008 72011 Available within the spare part set Part no Designation 72000 Compressor casing 72005 Screw plug 72006 Gasket 72008 Washer 72011 Hexagon head screw 72026 Stud 72027 Hexagon nut 72028 Washer 72060 Insulation 77000 Wall insert 77015 Socket screw 77040 O ring 79000 Diffuser Table 68 Spare parts Compressor casing Page 139 147 ...

Page 142: ...1266 81008 81007 81269 81273 81272 if provided Part no Designation 81000 Filter silencer complete 81004 Orifice 81005 Screw plug 81006 Gasket 81007 Screw plug 81008 Gasket 81135 Silencer body 81136 Absorption segment 81137 Cover sheet metal 81140 Cleaning nozzle 81141 Pressure spring 81265 Filter ring 81266 Cover grid 81269 Connection rod 81272 Hexagon head screw 81273 Hexagon nut Table 69 Spare p...

Page 143: ...ion branch radial 82140 82143 82006 82141 82006 82004 82005 82000 82170 82008 82007 if provided Part no Designation 82000 Air suction branch 82004 Orifice 82005 Screw plug 82006 Gasket 82007 Screw plug 82008 Gasket 82140 Cleaning nozzle 82141 Pressure spring 82143 Screw plug 82170 Screw plug Table 70 Spare parts Air suction branch radial Page 141 147 ...

Page 144: ...d 2 90328 Guide plate bolt 3 90336 Guide stud 1 90338 Mounting plate 1 90339 Socket screw 2 90441 Lifting spigot 1 90450 Support 2 90490 Guide stud 2 90802 Guide stud 3 90900 Press off screw 6 90901 2 Press off screw 3 90915 Press off screw 3 90916 1 Press off screw 5 90917 Press off screw 1 94003 Locking device 1 94006 Hexagon head screw 10 94007 Hexagon head screw 12 Table 71 Customer tool set 9...

Page 146: ...ion of water pressure vessel 62 Fig 30 Turbine and nozzle ring cleaning cycle 66 Fig 31 Cleaning cycle of turbine and nozzle ring with load ramp 67 Fig 32 Procedure Wet cleaning of turbine and nozzle ring 68 Fig 33 Weight of assemblies 78 Fig 34 Removing the filter silencer 79 Fig 35 Removing the air suction branch 80 Fig 36 Axial clearance 81 Fig 37 Removing wall insert 82 Fig 38 Transporting and...

Page 147: ...emoving the nozzle ring at the turbine end axial gas inlet casing 113 Fig 69 Installing the nozzle ring at the turbine end radial gas inlet casing 114 Fig 70 Installing the nozzle ring at the turbine end axial gas inlet casing 114 Fig 71 Tightening torques 1 116 Fig 72 Tightening torques 2 116 Fig 73 Flange tightening sequence 118 Fig 74 Fitting the locking device 121 Fig 75 Cover plate 01 spacer ...

Page 148: ...g operation Drop in speed 71 Table 25 Malfunctions during operation Speed in creases 71 Table 26 Malfunctions during operation Exhaust gas temperature too high 72 Table 27 Malfunctions during operation Charge air pressure too low 72 Table 28 Malfunctions during operation Charge air pressure too high 73 Table 29 Surging of the turbocharger 73 Table 30 Malfunctions when stopping Runout noises 74 Tab...

Page 149: ...ridge 132 Table 62 Spare parts Bearing casing 133 Table 63 Spare parts Rotor and bearing parts 134 Table 64 Spare parts Water vessel 135 Table 65 Spare parts Gas inlet casing axial 136 Table 66 Spare parts Gas inlet casing radial 137 Table 67 Spare parts Cleaning device for gas inlet casing 138 Table 68 Spare parts Compressor casing 139 Table 69 Spare parts Filter silencer 140 Table 70 Spare parts...

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