ABB A255-L35 Original Operation Manual Download Page 141

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Operation Manual / 4 Product description / A200-L

Figures

HZTL4036_EN

Revision R

October 2020

Figures

Fig. 1: Layout and function of the turbocharger ....... 5

Fig. 2: Warning plate locations ..................................... 7

Fig. 3: Locations of the rating plates ......................... 8

Fig. 4: Fitting the lifting gear...................................... 10

Fig. 5: Placing the turbocharger ................................. 11

Fig. 6: Compressor-end foot....................................... 12

Fig. 7: Turbine-end foot................................................ 12

Fig. 8: Oil temperature at the outlet.......................... 18

Fig. 9: Layout and overview of the speed measure-
ment system.................................................................. 20

Fig. 10: Replacing the speed sensor .......................... 22

Fig. 11: U-tube manometer at the filter silencer...... 23

Fig. 12: Noise insulation, bellows .............................. 25

Fig. 13: Layout and overview of filter silencer ......... 33

Fig. 14: Dismantling filter ring circumferential part....
35

Fig. 15: Opening filter ring lock.................................. 35

Fig. 16: Attaching new filter ring ............................... 36

Fig. 17: Fitting new filter ring ..................................... 36

Fig. 18: Overview of wet cleaning of compressor .. 39

Fig. 19: Filter plug view................................................ 40

Fig. 20: Overview of dry cleaning device.................. 42

Fig. 21: Drain pipe diagram......................................... 45

Fig. 22: Weights of assemblies ................................. 55

Fig. 23: Dismantling the filter silencer casing ........ 56

Fig. 24: Fitting the filter silencer casing ................... 57

Fig. 25: Fitting the filter silencer casing ................. 58

Fig. 26: Fitting the filter silencer casing ................. 58

Fig. 27: Fitting the filter silencer casing .................. 59

Fig. 28: Fitting the filter silencer casing .................. 59

Fig. 29: Fitting the bellows ......................................... 60

Fig. 30: Dismantling the filter silencer ...................... 61

Fig. 31: Dismantling the filter silencer...................... 62

Fig. 32: Dismantling the wall insert (A255-L.. - A260-
L..) ..................................................................................... 63

Fig. 33: Moving out wall insert .................................... 64

Fig. 34: Putting down wall insert ................................ 64

Fig. 35: Dismantling the wall insert (A265-L.. - A280-
L..) ..................................................................................... 65

Fig. 36: Moving out wall insert .................................... 66

Fig. 37: Putting down wall insert ................................ 66

Fig. 38: Putting down wall insert ................................ 67

Fig. 39: Dismantling the diffuser ............................... 68

Fig. 40: Measuring axial clearance A .......................... 69

Fig. 41: Removing the insulation (A275-L and smal-
ler)..................................................................................... 70

Fig. 42: Dismantling the gas inlet casing (275-L and
smaller) ............................................................................. 71

Fig. 43: Dismantling the nozzle ring (A275-L and
smaller) ............................................................................ 72

Fig. 44: Dismantling the gas inlet casing (A280-L) . 73

Fig. 45: Fitting the nozzle ring holder........................ 74

Fig. 46: Dismantling the nozzle ring .......................... 75

Fig. 47: Put down the nozzle ring................................ 75

Fig. 48: Fitting the nozzle ring (A275-L and smaller) ...
76

Fig. 49: Fitting the gas outlet casing (A275-L and
smaller) ............................................................................ 77

Fig. 50: Fitting the insulation (A275-L and smaller).....
78

Fig. 51: Fitting the nozzle ring (A280-L) ................... 79

Fig. 52: Attaching the nozzle ring (A280-L) .............. 80

Fig. 53: Fitting the gas inlet casing (A280-L) ........... 81

Fig. 54: Measuring axial clearance A .......................... 82

Fig. 55: Fitting the diffuser.......................................... 83

Fig. 56: Positioning wall insert.................................... 84

Fig. 57: Fitting the wall insert (A255-L.. - A260-L..) . 85

Fig. 58: Fitting the wall insert (A265-L.. - A280-L..) . 87

Fig. 59: Fitting the filter silencer ................................ 89

Fig. 60: Fitting the filter silencer ................................ 90

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Summary of Contents for A255-L35

Page 1: ... Turbocharging Operation Manual A255 L35 XAC23620 English Original Operation Manual Chapter Document ID 1 Introduction HZTL4005_EN_G 2 Safety HZTL4024_EN_E 3 Safety data sheet XAC23620 4 Product description HZTL4036_EN_R ...

Page 2: ...als 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 and the operating limits increases the risk of unpre dictable component failures ...

Page 3: ...of 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 spare parts 5 1 4 Contact information 7 ...

Page 4: ...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 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 Caution Warning Caution and warning signs are described in chapter Safety ABB Turbocharging ABB Switzerland Ltd Turbocharging is identified as ABB Turbocharging or as ABB Turbo Sys tems in this docume...

Page 6: ...ictogram 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 compa...

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 u Do not eat drink or keep food at the workplace while working with VCIs u Clean hands and face after working with VCIs u For further information refer to www branopac com Wear safety gloves to prot...

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 Turbocharging Service Station and repacked After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station Inspect the components Replace the desiccant agent Repackage...

Page 9: ...s 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 Switzerland Ltd Turbocharging Bruggerstrasse 71a CH 5401 Baden Switzerland www abb com turbocharging Page 7 7 ...

Page 10: ......

Page 11: ...mandatory signs 3 1 4 Definition of safety instructions 3 1 5 Intended use 4 1 6 Deflagration on gas engines 5 1 7 Warning plates on the turbocharger 6 1 8 Turbocharger rating plate 7 1 9 Periodic check of the pressure vessels 8 1 10 Lifting of loads 9 1 11 Prerequisites for operation and maintenance 10 1 12 Hazards during operation and maintenance 11 1 13 Safe operation 13 1 14 Safe maintenance 1...

Page 12: ...erials are a consequence of insufficient compliance with safety instructions are a consequence of insufficient or inappropriate performance of maintenance and in spection work The operating company is 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 o...

Page 13: ...spiratory 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 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 eve...

Page 14: ...ed with cooled exhaust gases via the low pressure exhaust gas recirculation EGR it must be ensured that these are cleaned as well as possible and that no water droplets or exhaust gas particles enter the compressor inlet The specific operating limits of the turbocharger were determined on the basis of informa tion from the enginebuilder about the intended use These data are given on the rating pla...

Page 15: ...o the tur bocharger or improper operation 1 6 Deflagration on gas engines ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar After a deflagration event ABB recommends verifying the following points on the turbochar ger Position of the turbine and compressor casings to the bearing casing Shifting of the bearing casing in relation to the bracket Cracks in casi...

Page 16: ...st always be present in the intended locations and must be legible Fig 1 Warning plate If warning plates are not present in the intended locations or are not legible they must be replaced with new warning plates The necessary information can be found in the Operation Manual Chapter 4 Product description Turbochargers supplied to the enginebuilder without insulation must be equipped later with warn...

Page 17: ...erwise 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 ...

Page 18: ...ax 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 rating plates are defined in the Operation Manual Chapter 4 Product description 1 9 Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging such as those for wet or dry cleanin...

Page 19: ...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 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 describ...

Page 20: ... Operation 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 ...

Page 21: ...ays wear ear protection u Always wear ear protection if the sound pressure level exceeds 85 dB A Wear ear protection Hazards due to hot surfaces Surfaces of the turbocharger attached parts and operating fluids lubricating oil get hot during operation The surface temperature depends on the efficacy of the existing insula tion The temperature may rise to a level that can cause burns WARNING Danger o...

Page 22: ...rotect 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 to be operated without filter silencer or air inlet casing With the engine stopped the rotor can rotate due to the stack draught alone u Operate the turbocharger in compliance with the specifications u Secure the ro...

Page 23: ...arry out any tests with regard to insulation resistance or voltage on the electrical components 1 13 Safe operation Mechanical hazards during operation During standard operation no mechanical hazards are caused by the turbocharger itself if it has been properly installed Safety during commissioning and operation u Visually inspect your working environment before starting work u Remove any obstacle...

Page 24: ...form 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 platf...

Page 25: ...ved u Observe the material safety data sheet for the cleaning agent or solvent u Wear personal protective equipment PPE according to the material safety data sheet u Inspect the electric cables for abrasion and damage before and after your cleaning work Safety during disassembly assembly maintenance and repair u Observe the procedures for set up service and inspection work and the inspection inter...

Page 26: ...rations 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 operati...

Page 27: ... in the material safety data sheet for the operat ing materials and supplies u Comply with local legislation Hazards due to the handling of insulation materials WARNING Danger from insulation materials 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 com...

Page 28: ......

Page 29: ...ion Manual A255 L35 Safety data sheet Page 1 1 Safety data sheet Copyright 2021 ABB All rights reserved XAC23620 April 2021 A255 L35 XAC23620 A255 L35 XAC23620 431 550 403 520 A255MK00271 2021 1500 36 100 100 ...

Page 30: ......

Page 31: ...ning after taking out of operation 16 4 Monitoring during operation 17 4 1 Oil pressure oil temperature 17 4 2 Admissible air inlet temperature 20 4 3 Turbocharger speed 20 4 4 Low pressure measurement at the filter silencer 23 5 Operation and service 24 5 1 Noise emission 24 5 2 Service work 25 5 3 Expected replacement intervals 29 5 4 Flexible turbocharger cut out 30 5 5 Stopping the engine 31 6...

Page 32: ...ling the nozzle ring A280 L 74 8 13 Fitting the nozzle ring A275 L 76 8 14 Fitting the gas inlet casing A275 L 77 8 15 Fitting the insulation A275 L 78 8 16 Fitting the nozzle ring A280 L 79 8 17 Fitting the gas inlet casing A280 L 81 8 18 Axial clearance A after assembly 82 8 19 Fitting the diffuser 83 8 20 Fitting wall insert 84 8 21 Fitting the filter silencer 88 8 22 Table of tightening torque...

Page 34: ...stions 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 understand ing Differences in detail are therefore possible 1 2 Registered trademarks The trademarks of outside companies are used in this document These are marked with the symbol 1 3 Related documents Ch...

Page 35: ...ber 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 Diffuser 04 Radial plain bearing 11 Compressor wheel 05 Gas outlet casing 12 Compressor casing 06 Turbine wheel 13 Air outlet silencer option 07 Nozzle ring Page 5 114 ...

Page 36: ...ir 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 optionally available If installed this will reduce the amount of noise generated by the components at the outlet side after the compressor cas ing The rotor runs in two radial plain bearings 03 04 wh...

Page 37: ...tes 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 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 equ...

Page 38: ...of the rating plates Copyright 2020 ABB All rights reserved HZTL4036_EN Rev R October 2020 1 6 Locations of the rating plates Fig 3 Locations of the rating plates One rating plate 01 each is attached on the left and the right side of the turbocharger bear ing casing Page 8 114 ...

Page 39: ...rd value specified here Product Weight of complete turbocharger unit kg A255 L 1350 A260 L 1550 A265 L 2600 A270 L 3800 A275 L 6300 A280 L 8700 Table 2 Total weight 2 2 Removing the turbocharger WARNING Risk of tipping If the turbocharger is not sufficiently supported or not supported at all dur ing removal and installation it may tip over and cause severe injury to per sonnel or accidents resulti...

Page 40: ...g the turbocharger Copyright 2020 ABB All rights reserved HZTL4036_EN Rev R October 2020 Fig 4 Fitting the lifting gear u Loosen fixing screws on compressor end and turbine end foot u Lift turbocharger from engine and put down in a suitable location u Cover oil connections Page 10 114 ...

Page 41: ...ger 2 3 1 Placing 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 fastening the turbocharger 12 while only slightly loosening the lifting gear u Remove lifting gear from turbocharger u Connect cable to speed sensor u Connect all gas air and oil pipes Page 1...

Page 42: ... 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 diameter Coefficient of friction 0 12 lightly oiled Table 3 General information about fastening the turbocharger Compressor end foot Fig 6 Compressor end foot u Tighten the foot fixing screws or nuts dia...

Page 43: ...6 1500 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 every 10 mm of ad ditional screw length b DEG A255 L M27 60 220 30 3 1 A260 L M27 60 220 30 3 1 A265 L M22 86 120 30 3 7 A270 L M27 100 220 30 3 1 A275 L M30 120 300 30 2 6 A280 L M33 136 400 35 2 6 Tab...

Page 44: ...with 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 at the inlet of the turbocharger is too high it can be reduced with a throttle valve The throttle valve is normally already fitted on the turbocharger and has been correctly set by the enginebuilder...

Page 45: ...m with warm oil u Use special running in filters when running in the engine and after all ser vice work on the lubricating system u Check that the oil filter is clean before commissioning u Check the oil pressure in the oil supply pipes Warning plates u Check whether warning plates are present and legible u Check whether the protective sheets have been removed from new warning plates 3 2 3 Checks ...

Page 46: ...ssembly 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 Service Station 3 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...

Page 47: ... 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 inlet of 30 65 C with an oil temperature range at the inlet of 65 85 C 0 6 0 8 0 8 1 0 Not admissible emergency stop with an oil temperature range at the inlet of 30 65 C with an oil temperature range a...

Page 48: ...e 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 to the current regulations Fig 8 Oil temperature at the outlet Status for operation Oil temperature at the ...

Page 49: ... ABB 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 the first moment after starting the engine u Activate the pre lubrication device each time before starting the engine The pre lubrication time is at least 5 minutes The post lubrication time is at le...

Page 50: ...ed 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 measurement cables 4 3 2 Layout and overview Fig 9 Layout and overview of the speed measurement system 86505 Speed sensor 86528 Tachometer 86506 O ring 42047 Screw plug 86515 Cable connector 32109 Se...

Page 51: ... 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 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 d...

Page 52: ... with a sealing lip and does not require a sealing disc for as sembly Fig 10 Replacing the speed sensor Part number A255 L A260 L A265 L A270 L A275 L A280 L 86505 M18x1 5 150 Nm M18x1 5 150 Nm M18x1 5 150 Nm M18x1 5 150 Nm M18x1 5 150 Nm M27x2 320 Nm Table 9 Tightening torques 86505 u Reduce the engine performance to idling and then stop the engine Pay attention to post lubrication Stopping the e...

Page 53: ...r 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 silencer Fig 11 U tube manometer at the filter silencer 81000 Filter silencer 81050 U tube manometer A mm H2O Pressure loss pressure difference If the turbocharger is operated at maximum engine powe...

Page 54: ...istance of 1 meter from the turbocharger The highest value of the emission sound pressure level1 reaches a maximum of 105 dB A near the air inlet The following prerequisites must be fulfilled with regard to the turbochar ger to observe this limit value Air inlet system has been fitted All standard noise reducing measures2 have been fitted Bellows at the air outlet has been acoustically insulated b...

Page 55: ...s 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 that is omitted or performed too late can cause excessive contamination wear and operating failures u Carry out the service work at the specified time intervals CAUTION Specific service interval Except...

Page 56: ...e is stopped in accordance with the instructions of the enginebuilder 5 2 3 Service work on turbocharger every 18000 hours It is recommended to have this service work and these checks carried out by an ABB Tur bocharging Service Station Damaged and worn out parts must be replaced with original ABB parts Take note of correct customer spare part set see chapter Ordering spare parts 103 u Remove and ...

Page 57: ...u Check axial clearance A u Clean wall insert diffuser and compressor casing and check for damage u Remove the gas inlet casing and dismantle the nozzle ring and cover ring u Clean the nozzle ring and cover ring and check for damage u Dismantle inspect and balance the rotor u Replace the plain bearing 5 2 5 Service work according to instructions of enginebuilder u Clean or replace the oil filter l...

Page 58: ...ng 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 Pressure loss in the filter si...

Page 59: ...cement 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 Expected replacement intervals for turbocharger parts HFO Heavy Fuel Oil Recommended replacement intervals h Rotor components See information on rating plate Bearings See information on rating plate Table 1...

Page 60: ...ulations 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 mal operation u During cut out operation the air outlet flap and gas inlet flap must be completely closed CAUTION Manual switching of the flaps If the gas inlet flap is opened during cut out operatio...

Page 61: ...on and service 5 5 Stopping the engine Copyright 2020 ABB All rights reserved HZTL4036_EN Rev R October 2020 5 5 Stopping the engine u Observe the instructions regarding post lubrication Pre lubrication and post lubrication 19 u Stop the engine Page 31 114 ...

Page 62: ...erved HZTL4036_EN Rev R October 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 trouble free functioning of the turbocharger Described maintenance points Filter silencer Compressor Turbine and nozzle ring Page 32 114 ...

Page 63: ...the 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 segment 81270 Tension band 81137 Sheet metal covering 81271 Lock 81265 Filter ring if present 81400 Water connection E Insert unit absorption segment sheet metal covering fitted Page 33 114 ...

Page 64: ...nd connecting strips 81268 see Fig 13 Layout and overview of fil ter silencer 33 u Pull out insert units E u Bend up the sheet metal coverings 81137 and remove the absorption segments 81136 u Clean the absorption segments 81136 When cleaning note that the absorption segments may only be cleaned lightly with pres surized air with a soft brush or a moist cleaning cloth Otherwise there is a danger of...

Page 65: ...R October 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 silencer installed Fig 14 Dismantling filter ring circumferential part u Dismantle circumferential part 9 Fig 15 Opening filter ring lock u Open the lock of the filter ring 81265 Page 35 114 ...

Page 66: ...g 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 ring is completely wrapped around the filter silencer u Undo the connection between the new and the old filter ring u Fasten the newly installed filter ring 81265 then fit circumferential part 9 Page 36...

Page 67: ...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 is completely dismantled and the compressor is mechanically cleaned Cleaning interval The interval between the cleaning cycles depends greatly on the operating conditions Cleaning should normally ...

Page 68: ...e 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 procedure is perfectly suitable provided that the contamination has not progressed too far Cleaning several turbochargers If several turbochargers are installed on an engine it is recommended to cle...

Page 69: ...damage 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 opening u Remove insulation from flange of filter silencer 81000 if present u Unscrew lock 81126 u Measure volume of water according to the following table u Pour this water into a clean can A u Caref...

Page 70: ...A275 L 3 0 A280 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 cast filter silen cer See chapter Design variants 61 Fig 19 Filter plug view Disassembly and checking of the filter plug 81125 is required if 20 seconds after the clean ing process water is still vi...

Page 71: ... 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 mechanically cleaned cannot be omitted Cleaning method The turbine and the nozzle ring are cleaned during operation using the dry cleaning method This cleaning method is tested and approved by ABB Turboc...

Page 72: ...ning 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 bar 18 Plate 14 Piping 19 Cleaning instructions 51717 15 On Off valve closed 51705 20 Gas inlet casing insulated CAUTION Protecting the pressurised air system u Protect the pressurised air system aga...

Page 73: ...remove 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 lever posi tion u Open the protection valve 16 u Open the on off valve 15 for cleaning the turbine for 3 4 minutes u Close the on off valve 15 u Close the protection valve 16 u Set the combined pressu...

Page 74: ...g 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 weight of the cleaning granulate must not exceed 1 2 kg dm3 Amount of granulate per turbocharger Product Quantity dm3 A255 L 0 6 A260 L 0 6 A265 L 1 0 A270 L 1 5 A275 L 2 0 A280 L 2 5 Table 14 Cleaning p...

Page 75: ...ter 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 pipe 01 set the drain cock 02 to position 1 A If the drain pipe 01 is blocked u Set the drain cock 02 to position 2 B and clean the drain pipe 01 with air from the compressor casing 04 If cleaning wit...

Page 76: ...ice 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 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 com...

Page 77: ...n 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 Service Station Engine Oil filter heavily contaminated Clean Oil pump in lubricating system defect ive Check replace Manometer displays incorrectly Replace manometer Table 18 Malfunctions during operati...

Page 78: ...igh 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 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 cont...

Page 79: ...3 Surging of the turbocharger Surging of the turbocharger Possible causes Remedy Turbocharger Filter silencer or diffuser contamin ated Clean Periodic maintenance 32 Heavy dirt deposits in the turbine or in the nozzle ring Engine Protective grating in front of the tur bocharger contaminated or damaged Clean replace Charge air cooler Cooler contaminated Clean Charge air duct blocked Table 23 Surgin...

Page 80: ...on 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 Turbocharger contaminated Clean Bearing damaged Contact an ABB Turbocharging Service Station Rotor rubbing Foreign object in the turbocharger Table 24 Malfunctions when stopping Runout noises Shortened run...

Page 81: ...on 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 is magnetic it can attract material particles This reduces the distance to the auxiliary bearing which can lead to amplification of the noise component and therefore to false triggering Dismantle the...

Page 83: ...assembly Tightening torques for components The specified tightening torques of the bolted connections must be observed Tightening torques for assembly devices Unless otherwise described the screws and nuts of the assembly devices supplied by ABB must be tightened in such a way that they are tight fitting WARNING Suspended loads Loads that are not attached according to regulations can cause injury ...

Page 84: ...eplaced Identification of the assembly devices Not all assembly devices 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 before and after use u Visually inspect for corrosion cracks deformation and wear u Damaged assembly devices must no longer be use...

Page 85: ...L A265 L A270 L A275 L A280 L 01 Filter silencer 180 230 350 470 850 1150 02 Wall insert 130 160 300 450 760 1070 03 Diffuser 25 25 40 60 110 160 04 Compressor cas ing 165 215 400 620 1030 1350 05 Cover ring 15 15 30 50 75 90 06 Nozzle ring 8 8 10 20 25 50 07 Gas inlet casing 135 135 180 240 380 520 Table 27 Weights of assemblies kg The total weight of the complete wall insert is made up of the wa...

Page 86: ...CE 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 disassembly must be carried out in reverse order of the assembly Fig 23 Dismantling the filter silencer casing 01 02 Bottom part 03 04 07 08 Side part 05 06 09 Circumferential part 10 11 Flange The co...

Page 87: ...f 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 filter silencer 81000 with screws A and B NOTICE Screw A The location of screw A serves as a reference for the correct assembly of the filter silencer casing u Before disassembling the bottom part 0...

Page 88: ...v R October 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 the screws on the filter silencer and on the bottom part u Fit the side parts 07 and 08 with the screws on the filter silencer on the bottom part and on the side parts 03 04 Page 58 114 ...

Page 89: ...r silencer casing Copyright 2020 ABB All rights reserved HZTL4036_EN Rev R October 2020 Fig 27 Fitting the filter silencer casing u Insert the flanges 10 and 11 laterally between the side parts and fit the screws Fig 28 Fitting the filter silencer casing u Fit the circumferential part 05 with the screws Page 59 114 ...

Page 90: ...e 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 screws of the bottom parts 01 and 02 u Tighten all screws of the side parts 03 04 07 08 and the flanges 10 11 u Tighten all screws of the circumferential parts 05 06 09 Bellows Fig 29 Fitting the bell...

Page 91: ...r variants Welded filter silencer Cast filter silencer The filter silencers 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 5 2 Dismantling the filter silencer welded u Dismantle the insulation if necessary Fig 30 Dismantling the filter silencer 1 Attach lifting gear to the eyelets of the filter silenc...

Page 92: ...rved HZTL4036_EN Rev R October 2020 8 5 3 Dismantling the filter silencer cast u Dismantle the insulation if necessary Fig 31 Dismantling the filter silencer 1 Attach the lifting gear to the front lug and rear eyelet of the filter silencer 81000 2 Loosen nuts 72004 and remove with washers 72003 3 Remove and put down filter silencer Page 62 114 ...

Page 93: ...L A260 L 1 Secure the wall insert 77000 with a hexagon nut 72004 2 Use the press off screws 90900 to press off the wall insert from the compressor cas ing 72000 until the lifting device 90190 can be fitted 3 Remove four threaded studs 72002 at the top so that the lifting device can be fitted 4 Fit shackle 90195 with lifting gear on P1 of lifting device 5 Fit lifting device with crane on upper area...

Page 94: ...served HZTL4036_EN Rev R October 2020 Fig 33 Moving out wall insert 7 Carefully move out the wall insert 77000 with diffuser 79000 8 Remove O ring 77040 Fig 34 Putting down wall insert u Put down wall insert 77000 with diffuser 79000 in horizontal position and use appro priate supports to prevent it from falling over and rolling away Page 64 114 ...

Page 95: ...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 the com pressor casing 72000 until the lifting device 90190 can be fitted 4 Fit shackle 90195 with lifting gear on P1 of lifting device 90190 5 Fit lifting device 90190 with crane on upper area of wall insert 77000 6 Change ...

Page 96: ...L4036_EN Rev R October 2020 Fig 36 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 37 Putting down wall insert u Put down wall insert 77000 with diffuser 79000 in horizontal position and use appro priate supports to prevent it from falling over and rolling away Page 66 114 ...

Page 97: ... 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 wall insert may lead to serious injuries to persons or even to fatal accidents u If the wall insert is not tilted ensure that it is fixed correctly see Dis mantling wall insert Fig 38 Putting down wall...

Page 98: ...ntling wall insert and diffuser Copyright 2020 ABB All rights reserved HZTL4036_EN Rev R October 2020 Fig 39 Dismantling the diffuser 4 Loosen and remove screws 77015 5 Remove O rings 79020 79021 6 Attach lifting gear L to the diffuser 79000 7 Remove and put down diffuser Page 68 114 ...

Page 99: ...loves 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 the components assessed and if necessary replaced by an ABB Tur bocharging Service Station Fig 40 Measuring axial clearance A The axial clearance A of the rotor should always be measured before...

Page 100: ...on A275 L NOTICE Dry cleaning The dry cleaning does not have to be removed to dismantle the insulation Fig 41 Removing the insulation A275 L and smaller 1 Loosen and remove screws of insulation jackets 51200 from gas outlet casing 61001 2 Loosen and remove all connecting plates of insulation jackets 3 Remove insulation jackets 4 Detach flange connection between gas inlet casing 51001 and bellows P...

Page 101: ...ce 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 gas inlet casing until hand tight u If the nut 51087 cannot be removed with the maximum permissible loosening torque it can be heated or removed with an appropriate tool 1 Treat nuts 51087 with rust remover 2 Loose...

Page 102: ... the nozzle ring A275 L Copyright 2020 ABB All rights reserved HZTL4036_EN Rev R October 2020 8 10 Dismantling the nozzle ring A275 L Fig 43 Dismantling the nozzle ring A275 L and smaller 1 Loosen screws 56014 and remove with washers 56011 2 Remove and put down nozzle ring 56001 Page 72 114 ...

Page 103: ...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 maximum permissible loosening torque it can be heated or removed with an appropriate tool 1 Dismantle both halves of the insulation segment 51215 and remove with all fixing ele ments 2 Detach flange connection between gas inlet casing 51001 and bellows...

Page 104: ...zle ring A280 L Copyright 2020 ABB All rights reserved HZTL4036_EN Rev R October 2020 8 12 Dismantling the nozzle ring A280 L Fig 45 Fitting the nozzle ring holder 1 Remove screws B2 2 Fit the nozzle ring holder 90477 with screws B1 at the top of the flange of the gas inlet casing 51001 Page 74 114 ...

Page 105: ...e 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 front onto the nozzle ring holder 4 Screw the screws B2 into the nozzle ring holder 5 Remove screws B1 Fig 47 Put down the nozzle ring u Use the crane to remove and put down the nozzle ring 56001 Page ...

Page 106: ...temperature grease u Coat the screw threads with high temperature grease Fig 48 Fitting the nozzle ring A275 L and smaller Product Size Tightening torque Nm A255 L M10 35 A260 L M10 35 A265 L M10 35 A270 L M10 35 A275 L M10 35 Table 33 Tightening torque 56014 1 Align the notch A1 with the flange connection A2 and slide the nozzle ring 56001 into the gas inlet casing 51001 2 Fit screws 56014 with h...

Page 107: ...6 301 140 A265 L M16 301 140 A270 L M18 401 200 A275 L M22 501 380 Table 34 Tightening torque 51087 1 Pre tightening torque of the nuts 1 Coat threaded stud 51086 with high temperature grease 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 Push gas inlet casing over the threade...

Page 108: ... torque and then to the tightening torque 6 Remove the lifting gear 7 Connect the flange of the gas inlet casing and the bellows 8 15 Fitting the insulation A275 L Fig 50 Fitting the insulation A275 L and smaller 1 Fit flange connection between gas inlet casing 51001 and bellows 2 Fit the insulation jackets 51200 on the gas inlet casing 51001 with the screws 3 Fit connecting plates of insulation j...

Page 109: ... Copyright 2020 ABB All rights reserved HZTL4036_EN Rev R October 2020 8 16 Fitting the nozzle ring A280 L u Coat the screw threads with high temperature grease Fig 51 Fitting the nozzle ring A280 L u Use lifting gear to secure the nozzle ring 56001 on the nozzle ring holder 90477 and transport it Page 79 114 ...

Page 110: ...4 M12 65 Nm Table 35 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 A1 on the cam of the nozzle ring 56001 with the flange connection A2 and slide the nozzle ring into the gas inlet casing 4 Coat screws 56014 with high temperature grease and fit with washers 56011 5 Remove screws B1 along wi...

Page 111: ...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 supports 90481 90482 from the gas inlet casing 4 Push gas inlet casing over the threaded studs up to the gas outlet casing 5 Coat two nuts with high temperature grease and fix gas outlet casing in two opposite positions 6 Coat remaining nut...

Page 112: ... 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 the components assessed and if necessary replaced by an ABB Tur bocharging Service Station Fig 54 Measuring axial clearance A The axial clearance A of the rotor should always be measured before and ...

Page 113: ...ize Tightening torque Nm A255 L M5 6 A260 L M5 6 A265 L M5 6 A270 L M6 10 A275 L M8 25 A280 L M8 25 Table 38 Tightening torque 77015 1 Attach lifting gear L to the diffuser 79000 2 Carefully place the diffuser on the wall insert 77000 then remove lifting gear 3 Fit new O rings 79020 79021 on the diffuser 4 Degrease screws 77015 and threaded holes in wall insert 5 Coat threads of the screws with Lo...

Page 114: ...nd assembly 8 20 Fitting wall insert Copyright 2020 ABB All rights reserved HZTL4036_EN Rev R October 2020 8 20 Fitting wall insert Fig 56 Positioning wall insert u Carefully bring wall insert 77000 into vertical position with the lifting device 90190 Page 84 114 ...

Page 115: ...ng 77040 to the wall insert 77000 2 Fit two guide studs 90320 in the upper area of the compressor casing 72000 Leave the top threaded hole x in the compressor casing empty 3 Align arrow markings of wall insert 77000 and compressor casing to one another 4 Carefully move the wall insert with diffuser 79000 over the guide studs into the com pressor casing Check the correct alignment of the wall inser...

Page 116: ...the wall insert fully in and remove the guide studs Fit the remaining threaded studs Observe tightening torque Leave the top threaded hole x in the compressor cas ing empty 8 Check that 23 threaded studs have been fitted 9 Press the wall insert into the compressor casing using a hexagon nut 72004 and sleeve 90191 Observe tightening torque Remove nuts and sleeves Page 86 114 ...

Page 117: ...s 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 diffuser 79000 over the guide studs into the com pressor casing Check the correct position of both casings using the marking arrows 5 Fit a screw 72011 as a safeguard 6 Remove the shackle 90195 with lifting gear Change the p...

Page 118: ...tober 2020 8 21 Fitting the filter silencer 8 21 1 Design variants The turbocharger is equipped with one of the following filter silencer variants Welded filter silencer Cast filter silencer The filter silencers differ in terms of the fixing eyelets for the lifting gear The relevant vari ant must be taken into consideration for disassembly and assembly Page 88 114 ...

Page 119: ...r welded Fig 59 Fitting the filter silencer Product Size Tightening torque Nm A255 L M16 265 A260 L M16 265 A265 L M14 130 A270 L M16 200 A275 L M18 300 A280 L M20 420 Table 42 Tightening torque 72004 1 Attach lifting gear to the eyelets of the filter silencer 81000 2 Position filter silencer on compressor casing 3 Fit nuts 72004 with washers 72003 and tighten u Fit insulation as far as necessary ...

Page 120: ...lencer cast Fig 60 Fitting the filter silencer Product Size Tightening torque Nm A265 L M14 130 A270 L M16 200 A275 L M18 300 A280 L M20 420 Table 43 Tightening torque 72004 1 Attach the lifting gear to the front lug and rear eyelet of the filter silencer 81000 2 Position filter silencer on compressor casing 3 Fit nuts 72004 with washers 72003 and tighten u Fit insulation as far as necessary Page ...

Page 121: ...sembly and assembly 8 22 Table of tightening torques Copyright 2020 ABB All rights reserved HZTL4036_EN Rev R October 2020 8 22 Table of tightening torques Fig 61 Overview of tightening torques Fig 62 Overview of speed sensor tightening torque Page 91 114 ...

Page 122: ...16 265 M14 130 M16 200 M18 300 M20 420 63a 72002 M16 60 M16 60 M14 40 M16 60 M18 80 M20 100 64 77015 M5 6 M5 6 M5 6 M6 10 M8 25 M8 25 65 56014 M10 35 M10 35 M10 35 M10 35 M10 35 M12 65 66 81125 G1 2 45 G1 2 45 G1 2 45 G1 2 45 G1 2 45 G1 2 45 67 86505 M18x1 5 150 M18x1 5 150 M18x1 5 150 M18x1 5 150 M18x1 5 150 M27x2 320 Table 44 Overview of tightening torques 1 Tighten crosswise 2 Pre tightening to...

Page 123: ...vice 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 regulations in the event of an emergency u The permissible turbocharger speed for the unlocked turbocharger may not exceed nBmax Take note of the rating plate u After locking the turbocharger contact an A...

Page 124: ...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 engine u Close off oil supply to defective turbocharger u Dismantle filter silencer see chapter Dismantling the filter silencer 61 u Lock rotor with locking device see chapter Locking the rotor 95 Version...

Page 125: ...ous damage to engine or property can be caused by ex cessive 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 if necessary u Stop the engine u Close off oil supply to defective turbocharger u Blank off the inlets and outlets of the defective turbocharger ...

Page 126: ... the locking device to a fin of the wall insert 77000 and align the hole circle to the drill holes in the compressor wheel 25000 5 Secure the locking device to the compressor wheel with the maximum possible number of screws B1 Observe tightening torque Assembly with at least 6 screws is mandatory The maximum possible number of screws to be fitted B1 varies as the threads in the compressor wheel ar...

Page 127: ... 57001 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 64 Ensuring clamping of the cover ring Product h mm d1 mm d2 mm A255 L 3 5 4 0 10 16 A260 L 3 5 4 0 10 16 A265 L 3 5 4 0 13 20 A270 L 3 5 4 0 13 20 A275 L 4 0 5 0 17 28 A280 L 4 0 5 0 21 34 Table 48 Required washers ...

Page 128: ...argers 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 positions where to fit the cover plates Fig 65 Position of cover plates u Stop the engine u Shut off the supply of lubricating oil to the turbocharger u Blank off flanges of compressor casing outlet 0...

Page 129: ...Manual 4 Product description A200 L 9 Taking a turbocharger out of operation 9 2 Taking defective tur bochargers out of operation Copyright 2020 ABB All rights reserved HZTL4036_EN Rev R October 2020 Page 99 114 ...

Page 130: ...ring 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 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...

Page 131: ...arts 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 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...

Page 132: ...spiratory 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 felt an...

Page 133: ...B 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 available for the work described in the op eration manual The customer spare part set required depends on the service work being carried out on the turbocharger The parts are only available in the complet...

Page 134: ...mer 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 51 Customer spare part set 97071 u Dispose of replaced parts and parts that are not reusable in a professional and environ mentally compatible manner Page 104 114 ...

Page 135: ... A200 L 12 Spare parts 12 2 View of turbocharger with part numbers Copyright 2020 ABB All rights reserved HZTL4036_EN Rev R October 2020 12 2 View of turbocharger with part numbers Fig 66 View of turbocharger with part numbers Page 105 114 ...

Page 136: ... nut 57001 Cover ring 57005 Hexagon head screw 61001 Gas outlet casing 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 screw 74040 Air outlet silencer option 74042 Gasket option 77000 Wall insert 77015 in the customer spare part set Hexagon head screw 77040 in the cust...

Page 137: ...bers Copyright 2020 ABB All rights reserved HZTL4036_EN Rev R October 2020 12 3 View of cartridge group with part numbers Fig 67 View of cartridge group with part numbers NOTICE Cartridge group The cartridge group is not delivered as a fitted assembly Spare parts must be ordered individually Page 107 114 ...

Page 138: ...g compressor end 32102 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 Hexagon head screw 42041 Gasket 42059 Hexagon head screw 42064 Hexagon head screw 42185 Socket screw 42186 O ring 42295 Pressure adjusting unit 42300 Partition wall 42305 O ring 4...

Page 139: ...12 94007 Screws 12 94020 Bracket 1 Table 54 Customer tool set 90000 A255 L A260 L A265 L 90000 Designation Quantity 90011 Wooden crate 1 90190 Lifting device 1 90195 Shackle 2 90317 Guide stud 3 90320 Guide stud 3 90900 Press off screw 3 90924 Press off screw 1 94003 Locking device 1 94020 Bracket 1 Table 55 Customer tool set 90000 A265 L A270 L A275 L 90000 Designation Quantity 90011 Wooden crate...

Page 140: ...e stud 3 90320 Guide stud 3 90477 Nozzle ring holder 1 90481 Support left 1 90482 Support right 1 90900 Press off screw 6 90924 Press off screw 1 94003 Locking device 1 94020 Bracket 1 Table 57 Customer tool set 90000 A280 L This tool set can be ordered from any ABB Turbocharging Service Station The following spe cifications must be included in the order Turbocharger type Designation and part numb...

Page 141: ...itting the filter silencer casing 59 Fig 29 Fitting the bellows 60 Fig 30 Dismantling the filter silencer 61 Fig 31 Dismantling the filter silencer 62 Fig 32 Dismantling the wall insert A255 L A260 L 63 Fig 33 Moving out wall insert 64 Fig 34 Putting down wall insert 64 Fig 35 Dismantling the wall insert A265 L A280 L 65 Fig 36 Moving out wall insert 66 Fig 37 Putting down wall insert 66 Fig 38 Pu...

Page 142: ...Fig 61 Overview of tightening torques 91 Fig 62 Overview of speed sensor tightening torque 91 Fig 63 Locking the rotor 95 Fig 64 Ensuring clamping of the cover ring 97 Fig 65 Position of cover plates 98 Fig 66 View of turbocharger with part numbers 105 Fig 67 View of cartridge group with part numbers 107 Page 112 114 Page 112 114 ...

Page 143: ...rge air pressure too high 49 Table 23 Surging of the turbocharger 49 Table 24 Malfunctions when stopping Runout noises 50 Table 25 Malfunctions when stopping Shortened runout time 50 Table 26 Malfunctions of the speed measurement system 51 Table 27 Weights of assemblies kg 55 Table 28 Weight of wall insert kg 55 Table 29 Tightening torques filter silencer screws 60 Table 30 Axial clearance A 69 Ta...

Page 144: ...Operation Manual 4 Product description A200 L Tables Copyright 2020 ABB All rights reserved HZTL4036_EN Revision R October 2020 Table 57 Customer tool set 90000 A280 L 110 Page 114 114 Page 114 114 ...

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ABB A255-L35, Original Operation Manual

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