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ABB HT557844 Operation Manual Download Page 114

Operation Manual / 4 Product description / A150-M.. - A155-M.. 

 

 

8 

Dismantling and fitting 

Page 82 / 120 

 

 

© Copyright 2017 ABB. All rights reserved. 

HZTL4032_EN 

Revision F 

January 2017 

 

 

If the cartridge group cannot be loosened, the press-off tool (90042) can be used (see chapter 

Pressing off the casing [➙ 

79]). 

 

Figure 38: Removing cartridge group 2 

1.  Attach lifting gear to cartridge group. 
2.  Treat threads of studs (51006) with penetrating oil and leave to take effect. 
3.  Loosen nuts (51007) and remove Verbus Ripp® washers (51003) together with fastening 

strips (51002). 

4.  Pull the cartridge group from the turbine casing and remove it. 
5.  Remove the centering bush (42193) and the threaded rod (42191) along with the clamping 

nut (42201). 

6.  Attach the cartridge group to the service support (90012). 
7.  If present: Remove the metal C-ring (51105). 

Summary of Contents for HT557844

Page 1: ...arging Operation Manual A155 M56 HT557844 English Original Operation Manual Chapter Document ID 1 Introduction HZTL4005_EN_E 2 Safety HZTL4022_EN_D 3 Safety data sheet HT557844 4 Product description HZTL4032_EN_F ...

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: ...ents Page 1 8 Copyright 2016 ABB All rights reserved HZTL4005_EN Revision E July 2016 Introduction 1 Introduction 3 1 1 Purpose of the manual 3 1 2 Symbols definitions 4 1 3 Storage of new turbochargers and spare parts 6 1 4 Contact information 8 ...

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Page 5: ...plains the turbocharger and contains instructions for safe operation 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 A...

Page 6: ...rk 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 Turbo Systems ABB Turbo Systems Ltd is identified as ABB Turbo Systems in this document Official service stations of ABB Turbo Sy...

Page 7: ...eaning Pictogram Meaning Tighten with specified torque Affix Tighten over specified tightening angle Measure Hand tight tighten without tools Note Oil Visually inspect Apply screw locking paste e g Loctite Please note text for numbered work step Apply high temperature grease See document Apply other paste in accordance with specifications Dispose of in an environmentally compatible professional wa...

Page 8: ...of the Ordinance on Hazardous Substances Nevertheless the following points must be observed when handling VCI Observe the information in the material safety data sheet Ensure proper space ventilation Do not eat drink or store food at the workplace while working with VCI Clean hands and face after working with VCI For more information see www branopac com Wear safety gloves to protect against mecha...

Page 9: ...y an ABB Turbocharging Service Station Check the package for damage If the package is damaged the turbocharger or cartridge group must be checked and repackaged by an ABB Turbocharging Service Station After every 3 years the following steps must be carried out by an ABB Turbocharging Service Station Checking the component Replacing the desiccant Repackaging the component NOTICE Replacement compone...

Page 10: ...hts reserved HZTL4005_EN Revision E July 2016 1 4 Contact information Contact information of the ABB Turbocharging Service Stations is available online Scan the QR code to access our website ABB Turbo Systems Ltd Bruggerstrasse 71a CH 5401 Baden Switzerland www abb com turbocharging ...

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

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Page 13: ...uence 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 operation of the turbocharger a...

Page 14: ...ask 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 instruc tions indicated by this symbol and the word WARNING can lead to serious injuries to personnel and even to fatal a...

Page 15: ... pressure required for operation The turbocharger is solely intended to be operated with a clockwise direction of rotation as viewed from the turbine end The specific operating limits of the turbocharger were determined on the basis of information from the enginebuilder about the intended use These data are given on the rating plate ABB accepts no liability and rejects all warranty claims for any ...

Page 16: ...charger or improper operation 1 6 Deflagration on gas engines ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar After a deflagration event ABB Turbo Systems recommends verifying the following points on the turbocharger Position of the turbine and compressor casings to the bearing casing Shifting of the bearing casing in relation to the bracket Cracks in cas...

Page 17: ... be present in the intended locations and must be legible Figure 1 Warning plate If warning plates are not present in the intended locations or are not legible they must be re placed 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 warning p...

Page 18: ...reed with the en ginebuilder 02 Turbocharger operating limits during operation Recommended inspection and replacement intervals of turbocharger components 03 Inspection interval of plain bearings in 1000 h 04 Replacement interval of compressor in 1000 h 05 Replacement interval of turbine in 1000 h Further data 06 Customer part number 07 Designation for special design 08 Weight of turbocharger in k...

Page 19: ...x and tMmax is not permitted Non observance of the recommended inspection and replacement intervals increases the risk of unpredictable component failures Locations of the rating plates The locations of the rating plates are defined in the Operation Manual Chapter 4 Product de scription 1 9 Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging such as those for wet ...

Page 20: ...t against mechanical hazards Wear safety helmet Figure 3 Attachment of loads on the crane hook Figure 4 Attachment angle If there are two or more suspension points the attachment angle of 45 must not be exceed ed This prevents excessive loading due to diagonal pull Before looping around the components of the turbocharger let them cool down maximum 80 C Attach components of the turbocharger as desc...

Page 21: ...table working materials and personal protective equipment must be kept in a perfect condi tion Only authorised personnel may remain in the vicinity of the turbocharger when the engine is running Competence of personnel The turbocharger must only be operated and serviced by trained and authorised personnel Basic mechanical training is a prerequisite Modifications to the turbocharger Modifications t...

Page 22: ...g always wear ear protection 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 insulation The temperature may rise to a level that can cause burns WARNING Danger...

Page 23: ... protect against thermal hazards Hazards due to rotating parts WARNING Physical hazards Contact with rotating parts can cause severe injury The turbocharger must never be used without the filter silencer or the air suction branch With the engine stopped the rotor can rotate due to the stack draught alone Operate the turbocharger in compliance with the specifications Secure the rotor against uninte...

Page 24: ...lectrical installations Do not carry out any tests with regard to insulation resistance or voltage on the electrical components 1 13 Safe operation Mechanical hazards during operation During standard operation no mechanical hazards are caused by the turbocharger itself if it has been properly installed Safety during commissioning and operation Visually inspect your working environment before start...

Page 25: ...ion and insulation can cause serious injuries to persons or even fatal accidents Only operate the turbocharger with burst protection fitted and insulation fitted in one of the following permitted variants Figure 5 Variant A Insulation 01 with integrated burst protection from ABB Turbo Systems Variant B Burst protection 03 and insulation 02 from ABB Turbo Systems Variant C Burst protection 03 from ...

Page 26: ...ch 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 Do not climb onto the turbocharger or onto attached parts and do not use them as climbing aids Use suitable climbing aids and working platforms for work above body he...

Page 27: ... Safety during disassembly assembly maintenance and repair Observe the procedures for set up service and inspection work and the inspection inter vals Inform the operating staff before starting any service or repair work Make sure the engine is not started while work is being conducted on the turbocharger Before taking off any cover or removing any guard from the turbocharger switch off the engine...

Page 28: ...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 turbo charger 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 materials and suppl...

Page 29: ...ation in the material safety data sheet for the operating materials and supplies 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 Only use suitable and non com...

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Page 31: ...peration Manual A155 M56 Safety data sheet Page 1 1 Safety data sheet Copyright 2017 ABB All rights reserved HT557844 February 2017 A155 M56 HT557844 A155 M56 HT557844 458 630 444 600 1650 12 50 50 2015 ...

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Page 33: ...urbocharger 12 2 3 Installing the turbocharger 15 3 Commissioning 21 3 1 Oil supply 21 3 2 Inspection procedures 23 3 3 Commissioning after taking out of operation 25 4 Monitoring operation 27 4 1 Oil pressure oil temperature 27 4 2 Exhaust gas temperature before turbine 29 4 3 Turbocharger speed 30 5 Operation and service 33 5 1 Noise emission 33 5 2 Service work 35 5 3 Expected replacement inter...

Page 34: ...ce B 84 8 11 Nozzle ring compression PD 85 8 12 Installing nozzle ring 86 8 13 Installing the cartridge group 87 8 14 Installing the compressor casing 89 8 15 Radial clearances N and R 91 8 16 Installing air inlets 92 8 17 Removing the turbine casing 93 8 18 Installing the turbine casing 96 8 19 Installing the gas outlet flange 97 8 20 Installing the gas outlet casing 99 8 21 Table of tightening t...

Page 35: ... contents Page 3 120 Copyright 2017 ABB All rights reserved HZTL4032_EN Revision F January 2017 12 Spare parts 113 12 1 Ordering spare parts 113 12 2 Required customer spare part set 97070 113 12 3 View of turbocharger with part numbers 114 Figures 117 Tables 119 ...

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Page 37: ... on questions regard ing 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 docu...

Page 38: ...and function of the turbocharger Figure 1 Layout and function of the turbocharger 01 Filter silencer air suction branch 08 Gas outlet flange 02 Compressor casing 09 Nozzle ring 03 Diffuser 10 Turbine casing 04 Bearing casing 11 Turbine end bearing flange 05 Axial thrust bearing 12 Compressor end bearing flange 06 Radial plain bearing 13 Compressor wheel 07 Turbine ...

Page 39: ...gine cylinders The rotor runs in two radial plain bearings 06 which are located in the bearing casing 04 between compressor and turbine The axial thrust bearing 05 is located between the two radial plain bearings The plain bearings are connected to a central lubricating oil duct which is normally supplied by the lubricating oil circuit of the engine The oil outlet always lies at the deepest point ...

Page 40: ...plates are not present in the designated locations or not readable proceed as fol lows Order new warning plates from ABB Turbocharging Service Stations Remove any warning plates that have become unreadable Clean and degrease the areas designated for the warning plates Fit new warning plates and remove protective sheets Turbochargers supplied to the enginebuilder without insulation must be equipped...

Page 41: ...on Page 9 120 Copyright 2017 ABB All rights reserved HZTL4032_EN Revision F January 2017 1 6 Locations of the rating plates Figure 4 Locations of the rating plates One rating plate 01 each is attached on the left and the right side of the turbocharger bearing casing ...

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Page 43: ...for removing and installing the turbo charger The following weight specification 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 Product Weights kg A150 M 1010 A155 M 1710 Table 2 Weights of turbocharger A150 M A155 M Figure 5 Suspension of complete turbocharger unit A Complete turb...

Page 44: ...essor wheel cooling opening with a screw plug 01 If present Disconnect the plug to the speed sensor 86505 and secure the rolled up cable on the turbocharger This protects the plug from being crushed Figure 6 Removing the turbocharger Treat threaded rods 42191 with penetrating oil and leave it on Secure the lifting gear to the turbocharger see illustration If present Detach the support 61301 from t...

Page 45: ... Do neither clean nor lubricate the pressure screws In case of non compliance it cannot be ensured that the necessary tension force is reached Do not clean pressure screws Do not lubricate pressure screws Figure 7 Loosening the clamping nut Working in a circle break loose all pressure screws of the clamping nut Working in a circle loosen each of the pressure screws by about of a turn 90 Repeat the...

Page 46: ...ed stably it may tip over This can result in serious personal injury Place the turbocharger on a clean level support Secure the turbocharger to prevent it from tipping over by using wooden beams and wedges and by taking the centre of gravity into account Figure 8 Turbocharger centre of gravity 01 Centre of gravity Remove turbocharger from engine support set it down properly in an appropriate place...

Page 47: ...CAUTION Inserting the gaskets Gaskets that are forgotten damaged or improperly inserted will lead to oil leaks Always use new gaskets and insert them carefully into the slot The necessary sealing is performed by O rings which are located in the slots of the bearing casing The O rings are supplied with the turbocharger Figure 9 Inserting the gasket 42001 Bearing casing 01 Oil supply 42200 O ring 02...

Page 48: ...e top 3 Place the thrust washer 01 of the clamping nut on the expansion bush and with the clamping nut screwed on guide the threaded rod through the thrust washer expansion bush and bearing casing Step B Preparing the positioning Screw the centering bush 42193 flush onto the threaded rod from below Clean the surface of the bracket the bearing casing the centering bush and the centering holes in th...

Page 49: ...ket and position using the centering bushes 42193 located in the bracket 5 Check value x If value x is not reached the turbocharger must be lifted up from the bracket and realigned Step D Fixing the threaded rod in place in the bracket Using the hexagon screw the threaded rod into the bracket up to value L If value L is not reached or the threaded rod jams while being screwed in the threaded rod m...

Page 50: ... that the necessary tension force is reached Do not clean pressure screws Do not lubricate pressure screws In order to correctly fit the clamping nuts the pressure screws 04 must not protrude from the clamping nuts 03 in the direction of the thrust washer 02 Make sure the pressure screws do not protrude in the direction of the thrust washer Figure 12 Preparing the clamping nut for the tightening p...

Page 51: ...A155 M36 85 Table 4 Pressure screw tightening torques 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 t...

Page 52: ...r wheel cooling CAUTION Failure of compressor wheel cooling Any prolonged failure of the compressor wheel cooling will shorten the re placement interval of the compressor wheel Make sure there is an uninterrupted supply of cooling air during operation Figure 14 Connecting the compressor cooling air intake Remove the screw plug on the connection for the compressor wheel cooling 06 and fit the cooli...

Page 53: ...uilder s specifications regarding the selection of lubricating oil and the oil change intervals 3 1 2 Pre lubrication Pre lubrication must be carried out as follows Switch on the oil pump Build up oil pressure see Table 5 Do not exceed a pre lubrication time of 2 minutes Start the engine Let the oil pump run until the pump driven by the engine generates sufficient pressure 3 1 3 Oil filtering Filt...

Page 54: ...rved HZTL4032_EN Revision F January 2017 3 1 5 Oil orifice in the bearing casing Figure 16 Oil orifice 01 Bearing casing 02 Oil orifice 03 Circlip With an oil inlet pressure of more than 3 bar with engine under load before the turbocharger the bearing casings are equipped as standard with an orifice at the oil inlet ...

Page 55: ...perty can be caused by dirt and solid mate rial particles in the oil For the initial commissioning phase and after all service work flush the complete lubricating system with warm oil Use special running in filters when running in the engine and after all ser vice work on the lubricating system Check that the oil filter is clean before commissioning Check the oil pressure in the oil supply pipes W...

Page 56: ... gas air and oil pipes for leaks 3 2 4 Checks when starting up the engine Measure speed oil pressure and charging pressure at various engine performances Measure the exhaust gas temperature before and after the turbine Measure the air temperature before and after the compressor Compare the measured values with the values of the acceptance certificate Different op erating conditions indicate a malf...

Page 57: ...emove the locking screw on the cooling air connection and fit the cooling air line General Check the exhaust gas pipe before and after the turbine for combustion residues or water residues and clean it Remove any foreign objects that may be present Check and clean filter silencer or air supply line and remove any foreign objects that may be present Put engine side oil circulation to the turbocharg...

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Page 59: ...upstream of orifice bar Normal operation 2 0 poil 4 5 Engine start Cold oil admissible for maximal 15 minutes 8 0 Engine idling admissible for maximal 1 hour 0 5 poil 2 5 Pre lubrication and post lubrication engine stopped 0 5 poil 1 0 Warning signal n 0 5 x nBmax 1 25 Alarm signal Not admissible Stop the engine immediately 0 6 Table 5 Lubricating oil pressure oil inlet 01 Turbocharger contact sur...

Page 60: ...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 spec ified oil outlet temperature is to be considered as alarm value for the turbocharger operation and must be monitored according...

Page 61: ...lacement intervals Operation above the operating limits defined on the rating plate can shorten the recommended replacement intervals considerably Measure exhaust gas temperature upstream of turbine Comply with operating limits on rating plate Definition and explanations concerning rating plate refer to chapter 2 of Operation Manual Safety Operating limits refer to chapter 3 of Operation Manual Sa...

Page 62: ...rger speed CAUTION Do not strain cables If you pull the speed measurement cables too hard contacts can be pulled out Do not strain the speed measurement cables by pulling 4 3 2 Layout and overview Figure 17 Layout and overview of speed measurement system 86505 Speed sensor 42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F I converter 01 Plug with integrated voltage limiter 86528 Tachomet...

Page 63: ...cannot be stopped it can continue to be driven at this reduced engine load or turbocharger speed If a turbocharger surges continuously the engine performance must be reduced further Measure the temperatures in the air lines and gas piping from and to the turbochargers and compare with normal values If clear deviations of temperature are found the nearest ABB Turbocharging Service Station has to be...

Page 64: ...d with a sealing lip and an O ring No additional gasket is required during assembly Figure 18 Replacing the speed sensor Part number A150 A155 86505 M12 x 1 5 15 Nm M12 x 1 5 15 Nm Table 8 Tightening torque 86505 Reduce the engine performance to idling and then stop the engine Pay attention to post lubrication Stopping the engine 40 Switch off the lubricating oil supply to the turbocharger Disconn...

Page 65: ... is measured at a distance of 1 meter from the turbocharger The highest value of the emission sound pressure level1 reaches a maximum of 105 dB A near the filter silencer The following prerequisites must be fulfilled with regard to the turbo charger 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...

Page 66: ...yright 2017 ABB All rights reserved HZTL4032_EN Revision F January 2017 Suggestion for noise insulation bellows Figure 19 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 67: ...d or performed too late can cause excessive contamination wear and operating failures Carry out the service work at the specified time intervals CAUTION Shortened service intervals Exceptional stresses such as several starts stops per day harsh environ mental conditions poor fuel quality or high system vibrations can lead to un timely machine damage even if the prescribed service intervals are ob ...

Page 68: ...00 hours after commissioning Clean or replace the oil filter located in the supply pipe to the turbocharger while the en gine is stopped 5 2 3 Service work according to instructions of enginebuilder Clean or replace the oil filter located in the supply pipe to the turbocharger while the en gine is stopped 5 2 4 Service work according to data on the rating plate Usually after 8000 12000 operating h...

Page 69: ...charger The following operating data and measured values must be entered regularly in the engine logbook of the enginebuilder Rating and speed of the engine Air intake temperature Pressure of the charge air Pressure loss in the charge air cooler Lubricating oil pressure and lubricating oil temperature If present Speed of the turbocharger Air temperature after the compressor and after the charge ai...

Page 70: ... for replacing the bearing parts and replacing the non rotating components exposed to hot gas A decisive role is played by various influencing parameters which in extreme cases can dras tically shorten the replacement interval of these parts During the prescribed periodic service work the individual parts are examined for wear and replaced if necessary Expected replacement intervals h MDO HFO Turb...

Page 71: ...e following influences Fuel quality and fuel treatment Load profile thermal cycling also number of starts stops emergency shutdowns operat ing point Gas inlet temperature Frequency and execution of cleaning process during operation Turbocharger specification System specific operating conditions combustion quality exhaust gas composition For bearing parts Lubricating oil quality oil filtering oil c...

Page 72: ... engine Run the engine for 5 10 minutes at idling speed before stopping it Observe the oil pressure specified for engine idling see Table 5 For oil cooled bearing casings post lubricate for 20 minutes if the turbine inlet temperature tTE exceeds the following values when the engine is stopped 550 C with insulated casing 600 C with non insulated casing At temperatures below the specified values pos...

Page 73: ...o be kept low while ensuring maximum fuel efficiency Maintenance interval Maintenance work Operating status 24 72 h 1 Cleaning the compressor during operation 42 Engine load 50 85 50 200 h 1 Cleaning the turbine during operation 46 Engine load 20 40 guideline value Similar to the service interval usually every 8000 12000 h 2 Cleaning components mechanically 50 Engine stopped Table 10 Maintenance t...

Page 74: ...taminated components cleaned mechanically by an ABB Turbocharging Service Station Periodic cleaning during operation does not replace the service work where the turbocharger is completely dismantled and serviced by an ABB Turbocharging Service Station Causes and results of contamination Contamination of the compressor stage depends on the degree of purity of the sucked in air Deposits can form in ...

Page 75: ...perating periods in the lower range of performance that both turbocharger compressors are cleaned 6 2 4 Function and safety of wet cleaning CAUTION Volume of water Uncontrolled volumes of water can damage the turbocharger and the en gine Never connect injection tubes directly to a water pipe or a larger metering container other than that specified by ABB Turbo Systems WARNING Danger due to pressur...

Page 76: ... filter silencer or air suction branch 02 Pressurized air inlet pipe 03 Valve activator Pressurized air from the compressor casing 72000 of the turbocharger passes through the pipe 02 to the water pressure vessel 27000 As soon as the valve activator 03 is activat ed water is pressed into the pipe 01 and routed to the filter silencer or air suction branch The water does not act as a solvent The coa...

Page 77: ... Parameters for wet cleaning of compressor Remove sealing plug 27005 Fill container with 0 4 dm3 of pure water Screw in sealing plug 27005 again Push the valve activator 03 against the spring and hold for 10 15 seconds until the entire volume of water is injected Continue to operate the engine for at least five minutes to ensure that all of the water is flushed out of the system Not more than thre...

Page 78: ...ace the service work where the turbocharger is completely dismantled and serviced by an ABB Turbocharging Service Station Cause and consequences of contamination ABB Turbo Systems recommends the use of fuels with low ash sulphur sodium and vanadi um contents The combustion of heavy fuel oil HFO in diesel engines causes contamination of the turbine stage Poor quality fuel in conjunction with high e...

Page 79: ...aning process with multiple short injection periods A turbine cleaning procedure with multiple short injection periods is recom mended only under certain circumstances If such a procedure is to be used this must be coordinated with ABB Turbo Systems Contact ABB Turbo Systems CAUTION Corrosion and deposits when cleaning Salt water and cooling water treatment substances damage and adversely affect t...

Page 80: ...bine cleaning 10 minutes Water supply ensured Water temperature 5 30 C External air supply optional Water pressure overpressure compared to atmosphere pWT 1 5 bar 2 5 bar External air pressure pPA 1 bar Table 12 Turbine wet cleaning recommended operating state The temperature at the turbine inlet can be up to 100 higher than the exhaust gas tem perature after the cylinder This must be taken into a...

Page 81: ...during this stabilisation phase If the cleaning result is unsatisfactory or there is water leakage contact an ABB Turbocharg ing Service Station Product Temperature before turbine before clean ing C Maximum tempera ture before turbine during cleaning C Water volume flow VW dm3 min 1 Injection time min A150 350 430 530 14 0 10 A155 350 430 530 19 0 10 Table 13 Wet cleaning of turbines parameters fo...

Page 82: ...ring Cleaning the filter ring if present Remove filter ring 81265 Clean filter ring 81265 as required or every 500 hours of operation and replace after the fifth cleaning process at the latest Contamination of the filter ring depends on the degree of purity of the sucked in air Rinse the filter ring 81265 with water and mild detergent or in the case of heavy contam ination soak and carefully push ...

Page 83: ...ion segments 81136 must only be cleaned lightly with compressed air a soft brush or a moist cleaning cloth Have any heavily contaminated absorption segments replaced by an ABB Turbocharging Service Station Fitting the filter silencer see Figure 22 Insert the absorption segments 81136 into the sheet metal coverings 81137 Bend the sheet metal coverings 81137 back to their original shape and insert i...

Page 84: ...rding to the material safe ty data sheet Comply with local legislation Wear safety goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mask to protect against gases The following parts which are relevant in terms of performance can be cleaned in accordance with the description below Figure 23 Compressor end non rotating parts 72000 Compressor casing 77000 Wall insert ...

Page 85: ...ly with local legislation Wear safety goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mask to protect against gases Baked layers of contamination for example from heavy fuel oil or coked oil occur at the tur bine end The following parts which are relevant in terms of performance can be cleaned in accordance with the description below Figure 24 Turbine end non rota...

Page 86: ...y after clean ing parts may corrode Immediately after cleaning install the cartridge group and put it back into operation There can be severe contamination of the compressor wheels due to badly filtered suction air and of the turbines because of heavy fuel oil operation or carbonized oil Cleaning during op eration may not suffice to remove such contamination instead it may need to be cleaned me ch...

Page 87: ...ntamination penetrates the cartridge group this can impair the function of the turbocharger and damage parts inside the cartridge group Make sure that no water or contamination can enter into the cartridge group Clean the compressor wheel with a rag or soft brush which has been soaked in water with a household cleaning agent Do not use wire brushes Dry the compressor wheel and the gap between the ...

Page 88: ... are described in the following Figure 25 Soaking the turbine end Product A mm B mm C mm A150 200 35 382 A155 240 40 454 Table 15 Value table for soaking To soak the layers of contamination on the turbine the cartridge group can be immersed verti cally in a container 02 with fluid Place the container 02 inside a larger container 03 so that the overflowing fluid can be collected CAUTION Selection o...

Page 89: ...harger and damage parts inside the cartridge group Place the cartridge group on suitable supports 01 made of wood or met al Observe dimension B for the supports 01 so that the cartridge group is not immersed too deeply Let the layers of contamination on the turbine soak for four hours Removing dirt WARNING Health hazard due to soot particles If soot particles enter the eyes or respiratory tract th...

Page 90: ...posits lead to rotor unbal ance This can result in bearing or turbocharger damage Remove all traces of contamination from the turbine After brushing off the dirt fill the container 02 with clean water and not with salt water Immerse the turbine of the cartridge group in clean water so that any loose dirt comes off Lift up the cartridge group and align it horizontally Clamp the partition wall to th...

Page 91: ... enginebuilder Turbocharger Rotor unbalance Contact ABB Turbocharging Service Sta tion Turbine or compressor damaged Bearing damaged Table 17 Malfunctions when starting Vibrations Rubbing of rotating parts Normal behaviour not a malfunction Turbocharger A minimal and uniform wear at the circumference of the rotor components caused by slight local rubbing against adjacent components is permitted Th...

Page 92: ...ce Manometer displays incorrectly Replace manometer Turbocharger Axial clearance of the rotor excessive Contact ABB Turbocharging Service Sta tion Table 19 Malfunctions during operation Lubricating oil pressure too low Speed reduces Possible causes Remedy Engine Defect on the connected cylinders in pulse charging Contact enginebuilder Turbocharger Turbine and or nozzle ring severely con taminated ...

Page 93: ...er too high Check clean cooling system Insufficient ventilation Improve ventilation Table 22 Malfunctions during operation Exhaust gas temperature too high Charge air pressure too low Engine performance and engine speed unchanged suction condition normal Possible causes Remedy Engine Air receiver not sealed Repair Gas piping between engine and turbine not sealed Injection mistimed Set correctly Va...

Page 94: ...rely contaminated or corroded compressor wheel can reduce the compressor wheel s fatigue endurance limit and result in the turbocharger being damaged Rectify malfunction in accordance with the following table Possible causes Remedy Turbocharger Compressor components severely con taminated by the ventilation gases that have been fed in Clean see chapter Periodic maintenance work 41 Optimize oil sep...

Page 95: ...se clarified and remedied immediately by an ABB Turbo charging Service Station Have parts assessed for damage and if necessary replaced by an ABB Turbocharging Service Station Possible causes Remedy Engine Protective grating in front of the turbo charger contaminated or damaged Clean replace Turbocharger Filter silencer or diffuser contaminated Clean see chapter Periodic maintenance work 41 Heavy ...

Page 96: ...e 28 Malfunctions when stopping Runout noises Runout time too short The runout time must be noted down as a reference Because the runout time depends on the oil viscosity the runout time must always be measured at the same oil temperature If the runout time is significantly shorter in comparison to a previous measurement the follow ing table must be observed Possible causes Remedy Turbocharger Tur...

Page 97: ...o chapter Ordering spare parts 113 Replacing the speed sensor 32 Table 30 Malfunction of the speed measurement system No signal or poor signal amplitude Measured speed too high Possible causes Remedy Turbocharger 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 amplification of the noise ...

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Page 99: ...t against mechanical hazards WARNING Danger of burns Touching hot surfaces can cause severe burns Do not touch hot surfaces Wear heat resistant safety gloves Clearly designate hot parts and assemblies when leaving the workplace Wear safety gloves to protect against thermal hazards CAUTION Further operations This Operation Manual may be used to carry out only those operations that are described in ...

Page 100: ...amaged assembly devices must no longer be used and must be re placed Customer spare part set Before starting operations make sure the required customer spare part sets are available See chapter Spare parts 113 Oil orifice When disassembling the turbocharger an oil orifice fitted in the oil inlet must not be re moved see also chapter Removing the cartridge group 80 Tightening torques for components...

Page 101: ...uspension 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 Assembly devices are specially constructed and designed for the defined use they are not commer cially available products Use assembly devices only for the described applications Lifting gear Equipment for...

Page 102: ...rounded up standard values Figure 26 Weights of assemblies Designation A150 kg A155 kg 01 Filter silencer 90 140 02 Radial air suction branch 24 40 03 Compressor casing 160 250 04 Wall insert 35 65 05 Diffuser 13 21 06 Cartridge group 220 360 07 Nozzle ring 8 13 08 Burst ring 11 17 09 Turbine casing 1 inlet 260 420 2 inlets 210 340 3 inlets 220 350 10 Gas outlet flange 35 65 11 Gas outlet casing 1...

Page 103: ... 3 Removing air inlets Mark the casing position for assembly Figure 27 Removing the air inlets 1 Attach lifting gear to the filter silencer 81000 or air suction branch 82000 2 Loosen the hexagon head screws 72051 and remove them with fastening strips 72012 3 Remove the filter silencer 81000 or air suction branch 82000 4 Remove and dispose of the O ring 81010 or 82010 ...

Page 104: ... 8 Dismantling and fitting Page 72 120 Copyright 2017 ABB All rights reserved HZTL4032_EN Revision F January 2017 8 4 Removing the gas outlet casing Removing the insulation Figure 28 Removing the insulation Remove the insulation of the gas outlet casing ...

Page 105: ...ition for assembly Figure 29 Removing the gas outlet casing 1 Fit swivel lifting eyes S to the gas outlet casing 61001 Secure lifting gear to the swivel lifting eye 2 Loosen and remove nuts 51009 3 If present Loosen the support 61301 from the bracket 4 Remove the gas outlet casing 61001 set it down properly in an appropriate place and secure it 5 Remove and dispose of the gasket 61002 ...

Page 106: ...gas outlet flange Depending on the way of fixing the gas outlet flange the appropriate Working Instruction has to be consulted pressing off using 3 or 6 press off screws If the following Working Instructions are not observed this can lead to cracks in the gas outlet casing The following variants are possible Pressing off using 3 press off screws Pressing off using 6 press off screws ...

Page 107: ... If necessary Treat the centering seat with rust remover through the press off threads and the clearance holes Mark the casing position for assembly Figure 30 Dismantling the gas outlet flange Product Press off screws to be used strength 8 8 Tightening torque A150 3 x M16 x 30 150 Nm A155 3 x M16 x 30 150 Nm Table 35 3 press off screws not included in the ABB Turbo Systems scope of delivery 1 Even...

Page 108: ...ecessary Treat the centering seat with rust remover through the press off threads and the clearance holes Mark the casing position for assembly Figure 31 Removing the gas outlet flange Product Press off screws to be used strength 8 8 Tightening torque A150 6x M12 x 30 65 Nm A155 6x M16 x 30 150 Nm Table 36 Press off screws gas outlet flange not included in the ABB Turbo Systems scope of delivery 1...

Page 109: ...assembly Figure 32 Removing the compressor casing 1 Attach swivel lifting eye S to compressor casing 72000 Secure lifting gear to the swivel lifting eye 2 Loosen screws 72011 and remove together with fastening strips 72012 3 Remove the compressor casing 72000 4 Remove and dispose of the O ring 42012 If the compressor casing cannot be loosened it can be pressed off against the turbine casing using ...

Page 110: ...rt Figure 33 Dismantling the diffuser and the wall insert 1 Loosen the screws 79041 and remove with fixing discs 79040 2 Remove diffuser 79000 3 Fit the swivel lifting eye S to the wall insert 77000 Secure lifting gear to the swivel lifting eye 4 Remove the wall insert 77000 When doing this make sure that the wall insert does not stick to the compressor casing 72000 5 Remove and dispose of the O r...

Page 111: ...017 8 7 Pressing off the casing CAUTION Axial force of the press off tool Using the press off tool 90042 a high level of axial force can be generated If the casing is pressed off with too much force on one side the rotor can be damaged Use the tool on both sides in alternation and make sure not to press off too hard on either side Figure 34 Press off the casing ...

Page 112: ...imit the oil flow rate through the bearing casing during operation engine under load to the admissible values an oil orifice is mandatory at the oil inlet of the bearing casing if the oil inlet pressure is 3 bar overpressure If an oil orifice is fitted in the oil inlet of the bearing casing it must not be removed Figure 35 Oil orifice 01 Bearing casing 02 Oil orifice 03 Circlip Removing the insula...

Page 113: ...ion X 1 Apply two marking lines M to the left and right of the cartridge group and the bracket 2 Support and fix the turbine casing 3 Loosen the clamping nut 42201 see Loosening the clamping nut 12 4 Screw threaded rod 42191 up to value X at the hexagon 5 Lift the centering bush 42193 using the threaded rod 42191 and hold it firmly If the centering bush jams Remove the clamping nut and rotate the ...

Page 114: ...moving cartridge group 2 1 Attach lifting gear to cartridge group 2 Treat threads of studs 51006 with penetrating oil and leave to take effect 3 Loosen nuts 51007 and remove Verbus Ripp washers 51003 together with fastening strips 51002 4 Pull the cartridge group from the turbine casing and remove it 5 Remove the centering bush 42193 and the threaded rod 42191 along with the clamping nut 42201 6 A...

Page 115: ... fitting Page 83 120 Copyright 2017 ABB All rights reserved HZTL4032_EN Revision F January 2017 8 9 Removing the nozzle ring Figure 39 Removing the nozzle ring 1 Pull out the nozzle ring 56001 with the two extraction devices 90070 2 Remove the lamellar sealing ring 56005 ...

Page 116: ...22 0 79 1 40 Table 38 Permissible clearances A and B 1 Move the rotor to and fro up to the stop In order to obtain a correct measurement elevate the turbine a little 2 Measure clearance A and compare it with the permissible values in the table 3 Raise the compressor and push the turbine down at the same time 4 Raise the turbine and push the compressor down at the same time 5 Measure clearance B an...

Page 117: ...clamped between the heat shield 42400 and the turbine casing 51000 Figure 41 Nozzle ring compression PD Product Compression PD mm A150 0 17 0 17 A155 0 17 0 17 Table 39 Permitted nozzle ring compression PD 42001 Bearing casing 51000 Turbine casing 42400 Heat shield 56001 Nozzle ring 1 Measure dimensions A B and S on cleaned surfaces 2 Calculate compression PD If the calculated value PD lies outsid...

Page 118: ...y 2017 8 12 Installing nozzle ring Figure 42 Installing the nozzle ring 1 Fit the lamellar sealing ring 56005 see A A When doing this pay attention to correct winding of the lamellar sealing ring see detail B 2 Align the cams on the nozzle ring with the recesses of the turbine casing 51000 3 Insert the nozzle ring 56001 into the turbine casing up to the stop ...

Page 119: ...ut of the service support 90012 4 Screw the clamping nut 42201 flush onto the threaded rod 42191 The hexagon of the thread screw is at the top Place the washer 01 of the clamping nut on the expansion bush and with the clamping nut screwed on guide the threaded rod through the washer expansion bush and bearing casing 5 Screw the centering bush 42193 flush onto the threaded rod from below 6 Lift the...

Page 120: ...to which the centering bush 42193 is inserted with screw grease 2 If present Insert the metal C ring 51105 3 Move the cartridge group into the turbine casing and align with the markings M made on the bracket at the time of disassembly 4 Rotate the clamping nut 42201 upwards up to the end of the threaded rod and insert the centering bush 42193 into the hole Check dimension X if dimension X is not r...

Page 121: ...wall insert and the diffuser Part number A150 A155 79041 M6 8 Nm M6 8 Nm Table 42 Tightening torque 79041 1 Fit a new O ring 77005 2 Fit the swivel lifting eyes S to the wall insert 77000 Secure lifting gear to the swivel lifting eye 3 Install the wall insert 77000 into the compressor casing and when doing so pay attention to the positioning pin in the compressor casing 4 Fit the diffuser 79000 wi...

Page 122: ...ning torque 72011 Always replace the O ring 42012 see chapter Spare parts 1 Thoroughly clean the fastening strips 72012 before assembly 2 Fit a new O ring 42012 3 Attach swivel lifting eye S to compressor casing 72000 Secure lifting gear to the swivel lifting eye 4 Install the compressor casing 72000 5 Install the fastening strips 72012 with screws 72011 Observe the tightening torque With the A155...

Page 123: ...irec tion N1 and lower direction N2 must be covered simultaneously 2 Calculate clearance N and compare it with the permissible values in the table 3 Push the feeler gauges 01 into the gap such that there is no clearance The upper direc tion R2 and lower direction R1 must be covered simultaneously 4 Calculate clearance R and compare it with the permissible values in the table CAUTION Clearances out...

Page 124: ...s Part number A150 A155 72051 M16 275 Nm M16 275 Nm Table 45 Tightening torque 72051 1 Attach lifting gear to the filter silencer 81000 or air suction branch 82000 2 Fit a new O ring 81010 to the filter silencer 81000 or a new O ring 82010 to the air suction branch 82000 3 Install the filter silencer 81000 or air suction branch 82000 4 Fit the fastening strips 72012 with hexagon head screws 72051 ...

Page 125: ...sing insulation supplied by ABB Turbo Systems also serves as a burst protection Serious injuries or accidents resulting in fatalities can occur if the turbine casing insulation supplied by ABB Turbo Systems is removed A burst pro tection is integrated into this turbine casing insulation supplied by ABB Turbo Systems For turbochargers which were ordered from ABB Turbo Systems without in sulation a ...

Page 126: ...escription A150 M A155 M 8 Dismantling and fitting Page 94 120 Copyright 2017 ABB All rights reserved HZTL4032_EN Revision F January 2017 Figure 49 Removing the insulation sheets Remove the insulation according to the illustration ...

Page 127: ...ismantled with the burst protection Ensure that the swivel lifting eye can be screwed in all the way Mark the casing position for assembly Figure 50 Removing the turbine casing 1 Fit swivel lifting eye S to the turbine casing 51000 Secure lifting gear to the swivel lift ing eye 2 Loosen nuts 51007 and remove together with Verbus Ripp washers 51003 and fas tening strips 51002 3 Remove turbine casin...

Page 128: ... its end position Figure 51 Installing the turbine casing Part number A150 A155 51007 M16 175 Nm M16 175 Nm 51101 M16 200 Nm M16 200 Nm Table 46 Tightening torque 51007 1 If present Fit the C ring 51105 2 Coat the threads of the studs 51006 with high temperature grease 3 Remove one of the upper screws 4 Fit swivel lifting eye S to the turbine casing 51000 Secure lifting gear to the swivel lift ing...

Page 129: ...s outlet flange Figure 52 Installing the gas outlet flange 1 If present Insert the metal C ring 57003 into the turbine casing 51000 and secure with high vacuum grease 2 Fit swivel lifting eye S to the gas outlet flange 57002 Secure lifting gear to the swivel lifting eye 3 Install gas outlet flange in turbine casing 51000 4 Measure radial clearance R see chapter Radial clearances N and R ...

Page 130: ...g Page 98 120 Copyright 2017 ABB All rights reserved HZTL4032_EN Revision F January 2017 Fitting the insulation of the turbine casing Figure 53 Fitting the insulation Fit the insulation according to the illustration Observe tightening torques see Table of tightening torques 101 ...

Page 131: ...umber A150 A155 51009 M16 200 Nm M16 200 Nm Table 47 Tightening torque 51009 1 Coat the thread with high temperature grease 2 Insert a new gasket 61002 into the gas outlet casing 61001 3 Fit swivel lifting eyes S to the gas outlet casing 61001 Secure lifting gear to the swivel lifting eye 4 Position the gas outlet casing correctly on the turbine casing 51000 5 If present Fit the support 61301 6 Fi...

Page 132: ... and fitting Page 100 120 Copyright 2017 ABB All rights reserved HZTL4032_EN Revision F January 2017 Fitting the insulation Figure 55 Fitting the insulation Fit the insulation according to the illustration Observe tightening torques see Table of tightening torques 101 ...

Page 133: ... Figure 56 Overview of tightening torques The following tightening torques must be observed for the designated screw fittings Position Part number A150 A155 02 72051 M16 275 Nm M16 275 Nm 04 79041 M6 8 Nm M6 8 Nm 08 51007 M16 175 Nm M16 175 Nm 09 51009 M16 200 Nm M16 200 Nm 11 72011 M16 275 Nm M18 370 Nm 15 86505 M12 x 1 5 15 Nm M12 x 1 5 15 Nm 16a M16 200 Nm M16 200 Nm Table 48 Tightening torques...

Page 134: ...ed HZTL4032_EN Revision F January 2017 Figure 57 Tightening torques for insulation The following tightening torques must be observed for the designated screw fittings Position Part number A150 A155 16b M12 65 Nm M12 65 Nm 18 M6 10 Nm M6 10 Nm 19 M8 25 Nm M8 25 Nm 20 M10 45 Nm M10 45 Nm Table 49 Tightening torques for insulation ...

Page 135: ...ly compatible manner Wear safety gloves to protect against thermal hazards CAUTION Directives for taking out of operation Serious damage to engine or property can be caused by non compliance with the directives for blanking the turbocharger off the engine Follow the directives of the enginebuilder If the engine has to be operated again as quickly as possible following a turbocharger defect then th...

Page 136: ...orrect handling of a cartridge group can damage the turbocharger and cause injuries to persons Have repairs to the cartridge group carried out by an ABB Turbocharging Service Station only To enable you to quickly put an engine back into operation after a turbocharger has sustained damage ABB Turbo Systems recommends having a replacement cartridge group available in storage see chapter Storage of n...

Page 137: ...owing section Gas outlet casing not removed Fit the turbine casing into the gas pipe and on the gas outlet casing again Attach the cover plate see following section Figure 58 Fitting the cover plate Make sure that the oil connections in the bracket are equipped with gaskets 1 Close opening in turbine casing 51000 with cover plate 01 2 Thoroughly clean the fastening strips 51002 before assembly 3 C...

Page 138: ...cluded in the ABB Turbo Systems scope of delivery and must be manufactured by the operating company according to the following drawing Material General structural steel in compliance with DIN EN 10025 2 Figure 59 Cover plate drawing Product B1 0 5 B2 B3 B4 0 2 B5 B6 0 1 B7 ØD1 0 2 ØD2 R1 M A150 138 9 135 240 21 4 2 0 320 71 4 413 6 33 196 M12 A155 164 6 160 286 5 25 5 2 0 385 84 6 492 39 232 M16 T...

Page 139: ... out of operation at short notice Page 107 120 Copyright 2017 ABB All rights reserved HZTL4032_EN Revision F January 2017 Figure 60 Dimensions for cover plate Product A B D1 D2 0 1 A150 90 10 90 0 2 28 2 A155 107 12 111 0 1 37 2 Table 51 Cover plate dimensions mm ...

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Page 141: ...reparations 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 Do not breathe in these substances and avoid contact with the skin Ensure proper ventilation Observe the information in the material safety data sheet for the operating materials and supplies Wear personal pr...

Page 142: ...ed separately The turbocharger is completely removed either as a whole unit or in individual parts For the measures always necessary for preparing the turbocharger parts for mothballing see section Taking the engine out of operation for up to 12 months subsection Preparations for mothballing If the turbocharger remains attached to the engine see section Taking the engine out of oper ation for up t...

Page 143: ...r safety goggles Wear 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 fi...

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Page 145: ...re not taken into account in this document contact an ABB Turbocharging Service Station Dispose of placed and unusable parts in an environmentally friendly and professional manner in accordance with the local regulations Dispose of the packaging of new parts in an environmentally friendly and professional manner in accordance with the local regulations 12 2 Required customer spare part set 97070 F...

Page 146: ...150 M A155 M 12 Spare parts Page 114 120 Copyright 2017 ABB All rights reserved HZTL4032_EN Revision F January 2017 12 3 View of turbocharger with part numbers Figure 61 Overview of part numbers only available in customer spare part set 97070 ...

Page 147: ...g 51002 Fastening strip 51010 Bearing casing insulation 51105 Metal C ring 51500 Burst protection 56001 Nozzle ring 56005 Lamellar sealing ring 57002 Gas outlet flange 57003 Metal C ring 57210 Burst ring 61001 Gas outlet casing 61002 in the customer spare part set Gasket 61301 Support 72000 Compressor casing 72011 Hexagon head screw 72012 Fastening strip 72060 Hood 72061 Insulating bush 77000 Wall...

Page 148: ...right 2017 ABB All rights reserved HZTL4032_EN Revision F January 2017 Part number Designation 86515 Cable connector 86526 F I converter 86528 Tachometer 97151 customer spare part set 6 nozzle turbine cleaning Table 53 Spare parts list Depending on the specification of the turbocharger ...

Page 149: ... Weights of assemblies 70 Fig 27 Removing the air inlets 71 Fig 28 Removing the insulation 72 Fig 29 Removing the gas outlet casing 73 Fig 30 Dismantling the gas outlet flange 75 Fig 31 Removing the gas outlet flange 76 Fig 32 Removing the compressor cas ing 77 Fig 33 Dismantling the diffuser and the wall insert 78 Fig 34 Press off the casing 79 Fig 35 Oil orifice 80 Fig 36 Removing insulation she...

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Page 151: ...ration Speed reduces 60 Table 21 Malfunctions during operation Speed increases 60 Table 22 Malfunctions during operation Exhaust gas temperature too high 61 Table 23 Malfunctions during operation Charge air pressure too low 61 Table 24 Malfunctions during operation Charge air pressure too high 62 Table 25 Malfunctions during operation Engine performance losses 62 Table 26 Malfunction Turbocharger ...

Page 152: ...erved HZTL4032_EN Revision F January 2017 Table 47 Tightening torque 51009 99 Table 48 Tightening torques 101 Table 49 Tightening torques for insula tion 102 Table 50 Cover plate dimensions mm 106 Table 51 Cover plate dimensions mm 107 Table 52 Customer spare part set 97070 113 Table 53 Spare parts list 115 ...

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