ABB HT564586 Operation Manual Download Page 115

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Operation Manual / 4 Product description / A100-L

Disassembly and assembly

Page 85 / 111

HZTL4034_EN

Revision F

June 2016

Fitting the wall insert

Figure 52: Positioning wall insert



Carefully bring wall insert (77000) into vertical position with the lifting device (90190).

Summary of Contents for HT564586

Page 1: ...arging Operation Manual A175 L37 HT564586 English Original Operation Manual Chapter Document ID 1 Introduction HZTL4005_EN_E 2 Safety HZTL4024_EN_C 3 Safety data sheet HT564586 4 Product description HZTL4034_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: ...rmity 3 1 3 Definition of mandatory signs 4 1 4 Definition of safety instructions 4 1 5 Intended use 5 1 6 Warning plates on the turbocharger 6 1 7 Turbocharger rating plate 7 1 8 Periodic check of the pressure vessels 8 1 9 Lifting of loads 9 1 10 Prerequisites for operation and maintenance 10 1 11 Hazards during operation and maintenance 11 1 12 Safe operation 13 1 13 Safe maintenance 14 ...

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Page 13: ...equence 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...

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

Page 15: ... These data are given on the rating plate ABB accepts no liability and rejects all warranty claims for any non intended uses WARNING Unapproved operation Any operation of the turbocharger outside of its operating limits can be haz ardous to personnel Only operate the turbocharger within its operating limits Only trained personnel must operate the turbocharger The intended use of the turbocharger i...

Page 16: ...ys 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...

Page 17: ...erwise agreed with the enginebuilder 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 T...

Page 18: ...x is not permitted Non observance of the recommended replacement intervals increases the risk of unpredicta ble 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 8 Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging such as those for wet or dry cleaning are so c...

Page 19: ...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 20: ...itable 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 ...

Page 21: ...ys 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 of bu...

Page 22: ...to protect against thermal hazards Hazards due to rotating parts WARNING Physical hazards Contact with rotating parts can cause severe injury The turbocharger must never be used without the 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 unin...

Page 23: ...ng on electrical installations Do not carry out any tests with regard to insulation resistance or voltage on the electrical components 1 12 Safe operation Mechanical hazards during operation During standard 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 befor...

Page 24: ...ve 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 height Comp...

Page 25: ... 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 and wa...

Page 26: ...u 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 sup...

Page 27: ...mation 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 co...

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Page 29: ...eration Manual A175 L37 Safety data sheet Page 1 1 Safety data sheet Copyright 2016 ABB All rights reserved HT564586 September 2016 A175 L37 HT564586 A175 L37 HT564586 254 550 243 520 5600 36 100 100 2016 ...

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Page 31: ...rbocharger 13 3 Commissioning 17 3 1 Oil supply 17 3 2 Inspection procedures 17 3 3 Commissioning after taking out of operation 19 4 Monitoring during operation 21 4 1 Oil pressure oil temperature 21 4 2 Turbocharger speed 23 4 3 Low pressure measurement at the filter silencer 27 5 Operation and service 29 5 1 Noise emission 29 5 2 Service work 30 5 3 Expected replacement intervals 34 5 4 Flexible...

Page 32: ...let casing and nozzle ring A175 L and smaller 72 8 9 Dismantling the gas inlet casing nozzle ring A180 L and larger 74 8 10 Fitting gas inlet casing nozzle ring and insulation A175 L and smaller 77 8 11 Fitting the gas inlet casing nozzle ring A180 L and larger 80 8 12 Axial clearance A after assembly 83 8 13 Fitting diffuser wall insert 84 8 14 Fitting the filter silencer 87 8 15 Fitting the filt...

Page 33: ...ble of contents Page 3 111 Copyright 2016 ABB All rights reserved HZTL4034_EN Revision F June 2016 12 1 Ordering spare parts 103 12 2 View of turbocharger with part numbers 104 12 3 View of cartridge group with part numbers 106 Figures 109 Tables 111 ...

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Page 35: ...ill be pleased to provide information 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 document...

Page 36: ... Layout and function of the turbocharger Figure 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 37: ...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 casing 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 casing The rotor runs in two radial plain bearings 03 04 which a...

Page 38: ...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 fitted later with w...

Page 39: ... Page 9 111 Copyright 2016 ABB All rights reserved HZTL4034_EN Revision F June 2016 1 6 Locations of the rating plates Figure 3 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 41: ... value specified here Product Weight kg A165 L 2300 A170 L 3300 A175 L 5600 A180 L 7500 A185 L 10500 A190 L 13500 Table 2 A100 L Weights 2 2 Removing the turbocharger WARNING Risk of tipping If the turbocharger is not sufficiently supported or not supported at all during removal and installation it may tip over and cause severe injury to personnel or accidents resulting in fatalities Support the t...

Page 42: ...age 12 111 Copyright 2016 ABB All rights reserved HZTL4034_EN Revision F June 2016 Figure 4 Fitting lifting gear to turbocharger Loosen fixing screws on compressor end and turbine end foot Lift turbocharger from engine and put down in a suitable location Cover oil connections ...

Page 43: ... turbocharger on the bracket Figure 5 Placing the turbocharger on the bracket Remove covers from the oil connections Align turbocharger and place on engine bracket Tighten fixing screws Steps for fastening the turbocharger 14 while doing this only slightly loosen the lifting gear Remove lifting gear from suspension eyes of the bearing casing Connect cable to speed sensor Connect all gas air and oi...

Page 44: ...compressor end a height of turbocharger foot a Dimension a turbine end a height of turbocharger foot F spacer sleeve D Value 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 Figure 6 Compressor end foot Tighten the foot fixing screws or nuts diagonall...

Page 45: ... Table 4 Tightening torques foot screws Angle controlled tightening Product Thread size Height a of foot mm Pre tightening torque Nm Tightening angle for height a DEG Additional tightening angle for every 10 mm of addi tional screw length b DEG A165 L M22 86 120 30 3 7 A170 L M27 100 220 30 3 1 A175 L M30 120 300 30 2 6 A180 L M33 136 400 35 2 6 A185 L M39 151 600 35 2 4 A190 L M42 167 700 35 2 2 ...

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Page 47: ... with a filter mesh width of 0 050 mm is sufficient for the turbo charger 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 enginebuilde...

Page 48: ...ust be thoroughly flushed 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 Warning plates Check whether warning plates are present and legible Check whether the protective sheets have been removed 3 2 3 Checks after comm...

Page 49: ...can liquefy or vaporise and es cape as oily fluids during the initial hours of operation Continuous escape of an oily fluid indicates an oil leak If there is a leak contact an ABB Turbocharging Service Station 3 3 Commissioning after taking out of operation If present Remove cover plates blind flanges on the compressor casing on the gas inlet as well as on the gas outlet General Check the exhaust ...

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Page 51: ...inlet of 30 70 C 0 8 2 5 Admissible for normal operation with an oil temperature range at the inlet of 70 85 C 0 8 2 0 Admissible during engine warm up 0 8 4 0 Temporarily admissible 1 h alarm 0 6 0 8 Not admissible emergency stop 0 0 0 6 Admissible during pre lubrication and post lubrication engine stopped 0 2 0 6 Table 6 Lubricating oil pressure oil inlet Lubricating oil temperature at the inlet...

Page 52: ...utlet C Admissible 45 110 Admissible 85 130 Temporarily admissible alarm 45 110 Temporarily admissible alarm 85 130 Not admissible stop engine 45 120 Not admissible stop engine 85 140 Table 8 Lubricating oil temperature at the outlet If the turbocharger was operated for a longer period of time outside of the admissible range ABB Turbo Systems recommends to have the turbocharger inspected by an ABB...

Page 53: ...AUTION Do not use cables as a climbing aid If you pull the speed measurement cables too hard contacts can be pulled out Do not tension the speed measurement cables 4 2 2 Layout and overview Figure 8 Layout and overview of the speed measurement system 86505 Speed sensor 86528 Tachometer 86506 O ring 42047 Screw plug 86515 Cable connector 32109 Sealing disc with cams 86526 F I converter Alternative ...

Page 54: ...the engine performance immediately to the point at which the maximum speed of all turbochargers does not exceed 70 of nBmax If the engine 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 exhaust gas pipes from and to the ...

Page 55: ... The speed sensor is designed with a sealing lip and does not require a seal ing disc for assembly Figure 9 Replacing the speed sensor Part number A165 L A170 L A175 L A180 L A185 L A190 L 86505 M18x1 5 150 Nm M18x1 5 150 Nm M18x1 5 150 Nm M27x2 320 Nm M27x2 320 Nm M27x2 320 Nm Table 9 Tightening torques 86505 Reduce the engine performance to idling and then stop the engine Pay attention to post l...

Page 56: ... during operation Page 26 111 Copyright 2016 ABB All rights reserved HZTL4034_EN Revision F June 2016 4 2 5 Malfunction of the speed measurement system The possible reasons for malfunction of the speed measuring system are described in chapter Troubleshooting ...

Page 57: ...mat An increased pressure loss indicates an increase in the fouling of the filter material 4 3 2 U tube manometer at the filter silencer Figure 10 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 power and pressure loss A reaches the value of 200 mm H2O Clean filter mat ...

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Page 59: ...easured 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 acou...

Page 60: ...on 05 Insulation mat at least 15 mm 06 Sheet metal cover 5 2 Service work Service work includes visual inspections monitoring measuring and inspection work as well as function checks Service work enables to detect and rectify changes to the turbocharger and ensures full operability of the turbocharger CAUTION Service intervals Service work on the turbocharger that are omitted or performed too late...

Page 61: ...vent machine damage caused by ageing and downtime we recom mend having an inspection carried out by an ABB Turbocharger Service Sta tion no later than 5 years after the last service 5 2 1 Service procedures every 25 50 hours CAUTION Unknown operational changes Impairment to the degree of a possible operating failure can be the conse quence Get an ABB Turbocharging Service Station to clarify unknow...

Page 62: ...so be carried out after disassembling the gas inlet casing Replace any damaged or worn parts with original parts from ABB Turbo Systems Fit the wall insert Install the filter silencer 5 2 4 Service work on turbocharger every 36000 hours The following work must be carried out by an ABB Turbocharging Service Station Replacement of the bearing parts Checking and assessment of the rotor Remove the fil...

Page 63: ...ne system enables conclusions to be drawn on the behaviour of the turbocharger The following 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 cool...

Page 64: ... 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 Turbocharger part Operation with HFO Gas inlet casing 50000 10...

Page 65: ...urbochargers can be operated with one turbocharger switched off The flexible switch on or switch off of a turbocharger is referred to as a flexible turbocharger cut out In flexible systems slide valves or flaps are installed by the enginebuilder before the gas inlet and after the air outlet of the turbocharger Depending on the version of the system the turbocharger can be switched off or on manual...

Page 66: ...ion CAUTION Automatic switching of the flaps During automatic flap control there is a risk of the turbocharger rotating op posite the intended direction of rotation if the air outlet flap is open further than the gas inlet flap during the switching process This can lead to damage on the turbocharger The turbocharger should only be switched on or off below charging pres sures of 0 3 bar Close the c...

Page 67: ...ed HZTL4034_EN Revision F June 2016 6 Periodic maintenance 6 1 Foreword to maintenance Maintenance work includes regular visual controls and cleaning operations which are intended to ensure the trouble free functioning of the turbocharger Described maintenance points Filter silencer Compressor Turbine and nozzle ring ...

Page 68: ...aning the filter silencer Filter silencer with tension band Figure 12 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 E Insert unit absorption segment sheet metal covering fitted ...

Page 69: ...n bands 81270 at the locks 81271 and remove them along with the cover grid 81266 and connecting strips 81268 see Figure 12 Pull out insert units E Bend up the sheet metal coverings 81137 and remove the absorption segments 81136 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 ...

Page 70: ... 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 Figure 13 Dismantling filter ring circumferential part Dismantle circumferential part 9 Figure 14 Opening filter ring lock Open the lock of the filter ring 81265 ...

Page 71: ... new filter ring Attach the new filter ring 81265 on the filter ring to be replaced so they overlap Figure 16 Fitting new filter ring Pull on the old filter ring until the new filter ring is completely wrapped around the filter silencer Undo the connection between the new and the old filter ring Fasten the newly installed filter ring 81265 then fit circumferential part 9 ...

Page 72: ...d compressor efficiency Higher exhaust gas temperatures Increased fuel consumption Increased rotor unbalance Periodic cleaning of the compressor during operation prevents or delays any great increase in the contamination but never replaces the regular service procedures where the turbocharger is completely dismantled and the compressor is mechanically cleaned Cleaning interval The interval between...

Page 73: ...ompressor stage during operation water is injected before the compressor wheel The water does not act as a solvent The coating is removed by the mechanical action of the impacting droplets The process is particularly suitable as long as the contamination is not too advanced Cleaning several turbochargers If several turbochargers are installed on an engine it is recommended to clean one compres sor...

Page 74: ... Unscrew lock 81126 Measure volume of water according to the following table Fill this water into a clean can A Carefully pour this water into the filling orifice B with the can Screw in lock and hand tighten Fit insulation on the flange of the filter silencer if present After cleaning allow the engine to continue to run for at least 5 minutes under normal load Repeating the cleaning If the cleani...

Page 75: ...g process The filling time is 4 15 seconds Checking the filter plug Figure 18 Filter plug view Disassembly and checking of the filter plug 81125 is required if 20 seconds after the clean ing process water is still visible in filler opening B Loosen and remove the filter plug 81125 with box spanner Clean the drill holes of the plug Fit filter plug 81125 Part number A165 L A170 L A175 L A180 L A185 ...

Page 76: ... contamination 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 Turbo Systems In...

Page 77: ...ure 19 Overview of dry cleaning device 11 Container for granulate material 51702 16 Protection valve closed 51713 12 Cover cap 51703 17 Pressurised air valve venting 51704 13 Pressurised air supply 4 10 bar 18 Plate 14 Piping 19 Cleaning instruction 51717 15 On Off valve closed 51705 20 Gas inlet casing insulated CAUTION Protecting the pressurised air system Protect the pressurised air system agai...

Page 78: ... 12 Fill the specified amount of granulate into the container 11 Screw on and tighten the cover cap 12 Open the combined pressurised air valve pressure release valve 17 down lever posi tion Open the protection valve 16 Open the on off valve 15 for cleaning the turbine for 3 4 minutes Close the on off valve 15 Close the protection valve 16 Set the combined pressurised air valve pressure release val...

Page 79: ...ranulated 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 A165 L 1 0 A170 L 1 5 A175 L 2 0 A180 L 2 5 A185 L 3 0 A190 L 3 5 Table 14 Amount of granulat...

Page 80: ...due to other causes the gas outlet casing can be drained Figure 20 Drain pipe diagram 01 Drain pipe A Position 1 02 Drain cock B Position 2 03 Drain 04 Air line from compressor casing On the drain pipe 01 set the drain cock 02 to position 1 A If the drain pipe 01 is blocked Set the drain cock 02 to position 2 B and clean the drain pipe 01 with air from the compressor casing 04 If cleaning with air...

Page 81: ...rger Rotor unbalance Contact ABB Turbocharging Service Sta tion Turbine or compressor damaged Bearing damaged Table 16 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 This causes the com press...

Page 82: ...ironmentally compatible manner Wear safety gloves to protect against thermal hazards Possible causes Remedy Engine Oil filter heavily contaminated Clean Oil pump in lubricating system defective Check replace Manometer displays incorrectly Replace manometer Turbocharger Axial clearance of the rotor excessive Contact ABB Turbocharging Service Station Table 18 Malfunctions during operation Lubricatin...

Page 83: ...heck 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 Engine Air receiver not sealed Repair Gas pipe between engine and turbine not sealed Injection mistimed Set correctly Valve control mis...

Page 84: ...igh 7 3 Surging of the turbocharger Surging of the turbocharger Possible causes Remedy Engine Protective grating in front of the turbo charger contaminated or damaged Clean replace Turbocharger Filter silencer or diffuser contaminated Clean Periodic maintenance 37 Heavy dirt deposits in the turbine or in the nozzle ring Charge air cooler Cooler contaminated Clean Charge air duct blocked Table 23 S...

Page 85: ...arger A surge blow is accompanied by a loud bang and escape of hot air from the filter silencer 7 4 Malfunctions when stopping Noises during run down Possible causes Elimination Turbocharger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Table 24 Malfunctions when stopping noises during run down Run down ...

Page 86: ...lectronics This problem is eliminated by removing the gasket Defective sensor Contact an ABB Turbocharging Service Station Measured speeds too high Contaminated sensor tip The sensor tip is magnetic and can thus attract metal particles As a result the distance to the auxiliary bearing decreases which can lead to amplification of the noise component and consequently to faulty triggering Remove the ...

Page 87: ...sembly ABB Turbo Systems recommends marking the casing positions prior to dis assembly 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 in the toolbox WARNING Servicing the assembly devices Assembly devices must be checked for damage before and after use Visually inspect for corrosion c...

Page 88: ...y functional lifting gear with sufficient load limit Pay attention to the correct attachment of loads on the crane hook People must not stand under suspended loads Wear safety gloves to protect against mechanical hazards Wear safety helmet Definition of terms Suspension point Defined loading point on a component or an assembly blind hole thread eyelet lug Assembly device Devices that are fitted on...

Page 89: ... L A175 L A180 L A185 L A190 L 01 Filter silencer 220 280 480 620 850 1050 02 Wall insert 240 340 560 820 1090 1500 03 Diffuser 40 60 100 140 200 270 04 Compressor casing 320 450 740 960 1360 1800 05 Cover ring 30 50 75 90 110 150 06 Nozzle ring 10 20 25 50 65 85 07 Gas inlet casing 180 240 380 520 700 810 Table 27 Weights of assemblies kg The total weight of the complete wall insert is made up of...

Page 90: ...e 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 Figure 22 Overview of filter silencer casing disassembly and assembly 01 02 Bottom part 03 04 07 08 Side part 05 06 09 Circumferential part 10 11 Flange The complet...

Page 91: ...ncer casing assembly Only this way is it possible to fit all the parts Do not tighten the screws during assembly Figure 23 Fitting filter silencer casing 1 Fit the bottom part 01 to 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 Before disassembling the bottom part 01 mark the locatio...

Page 92: ...16 Figure 24 Fitting filter silencer casing 2 Fit the bottom part 02 with the screws on the filter silencer Figure 25 Fitting filter silencer casing 3 Fit the side parts 03 and 04 with the screws on the filter silencer and on the bottom part 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 93: ...EN Revision F June 2016 Figure 26 Fitting filter silencer casing 4 Insert the flanges 10 and 11 laterally between the side parts and fit the screws Figure 27 Fitting filter silencer casing 5 Fit the circumferential part 05 with the screws Fit the circumferential part 06 with the screws Fit the circumferential part 09 with the screws ...

Page 94: ... silencer Screws for fastening the individual parts M10 30 Nm M8 25 Nm Table 29 Tightening torques filter silencer screws Tighten all screws of the bottom parts 01 and 02 Tighten all screws of the side parts 03 04 07 08 and the flanges 10 11 Tighten all screws of the circumferential parts 05 06 09 Bellows Figure 28 Fitting the bellows Fit bellows C with frame F screws S and nuts N on the filter si...

Page 95: ...ncer If the turbocharger is also fitted with a noise package observe the chapter on dismantling the filter silencer with noise package Dismantle the insulation if necessary Figure 29 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 96: ...if necessary Figure 30 Dismantling the filter silencer with noise package 1 Loosen and remove the insulation ring 81300 2 Attach the lifting gear to the front lug and rear eyelet of the filter silencer 81000 3 Loosen nuts 72004 and remove with washers 72003 and insulating discs 81302 4 Remove and put down filter silencer 5 Remove the gasket 81301 6 Loosen counter sunk screws 74043 remove with air ...

Page 97: ...leave 2 3 of the thread length screwed into the compressor 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 compressor 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 ...

Page 98: ...ion F June 2016 Figure 32 Moving out wall insert 7 Remove screw 72011 8 Carefully move out the wall insert 77000 with diffuser 79000 9 Remove the O ring 77040 Figure 33 Putting down wall insert Put down wall insert 77000 with diffuser 79000 in horizontal position and use appropri ate supports to prevent it from falling over and rolling away ...

Page 99: ...d even to fatal accidents 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 If the wall insert is not tilted ensure that it is fixed correctly see Disman tling wall insert Figure 34 Putting down wall insert 1 P...

Page 100: ...assembly Page 70 111 Copyright 2016 ABB All rights reserved HZTL4034_EN Revision F June 2016 Figure 35 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 101: ... Figure 36 Measuring axial clearance A The axial clearance A of the rotor should always be measured before and after service work on the turbocharger Measure and note axial clearance A Product Axial clearance A mm A165 L 0 32 0 62 A170 L 0 33 0 63 A175 L 0 38 0 68 A180 L 0 41 0 73 A185 L 0 43 0 77 A190 L 0 45 0 80 Table 30 Admissible axial clearance A CAUTION Clearances outside the tolerance Serio...

Page 102: ...d smaller Dismantling the insulation NOTICE Dry cleaning The dry cleaning does not have to be removed to dismantle the insulation Figure 37 Removing the insulation A175 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 in...

Page 103: ...nd remove all but two opposite screws 61009 2 Fit two guide studs 90317 in the upper area on the gas outlet casing 3 Loop around the gas inlet casing 51001 with lifting gear 4 Loosen and remove remaining screws 61009 5 Carefully move out gas inlet casing and put down remove guide studs Dismantling the nozzle ring Figure 39 Dismantling the nozzle ring A175 L and smaller 1 Loosen screws 56014 and re...

Page 104: ...80 L and larger 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 3 Loosen and remove all but two opposite screws 61009 4 Fit two guide studs 90317 in the upper area on the gas outlet casing 61001 5 Loop lifting gear around gas inlet casing 6 Loosen remaining screws and carefully move o...

Page 105: ...age 75 111 Copyright 2016 ABB All rights reserved HZTL4034_EN Revision F June 2016 Dismantling the nozzle ring Figure 41 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 106: ...arger 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 Figure 43 Putting down the nozzle ring A180 L and larger Use the crane to remove and put down the nozzle r...

Page 107: ... smaller Fitting the nozzle ring Coat the screw threads with high temperature grease Figure 44 Fitting the nozzle ring A175 L and smaller Part number A165 L A170 L A175 L 56014 M10 35 Nm M10 35 Nm M10 35 Nm Table 31 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 high temperature grea...

Page 108: ...ws 1 Fit two guide studs 90317 in the upper area on the gas outlet casing 61001 2 Loop around the gas inlet casing 51001 with the lifting gear and secure it to the crane 3 Push gas inlet casing over the guide studs up to the gas outlet casing 4 Screw in two opposite screws 61009 with high temperature grease 5 Remove the guide studs 90317 and fit the remaining screws 61009 with high temperature gre...

Page 109: ...N Revision F June 2016 Fitting insulation Figure 46 Fit insulation 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 jackets with screws 4 Fit insulation jackets with screws on gas outlet casing 61001 ...

Page 110: ...034_EN Revision F June 2016 8 11 Fitting the gas inlet casing nozzle ring A180 L and larger Fitting the nozzle ring Coat the screw threads with high temperature grease Figure 47 Looping around the nozzle ring A180 L and larger Loop around the nozzle ring 56001 with lifting gear on the nozzle ring holder 90477 and fix on the crane ...

Page 111: ... M12 65 Nm M12 65 Nm M16 170 Nm Table 33 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 Remov...

Page 112: ...s outlet casing 61001 2 Loop around the gas inlet casing 51001 with the lifting gear and secure it to the crane 3 Dismantle and remove support 90451 from the gas inlet casing 51001 4 Push gas inlet casing over the guide studs up to the gas outlet casing 61001 5 Coat two opposite screws 61009 with high temperature grease and screw in 6 Remove the guide studs 90317 7 Coat remaining screws 61009 with...

Page 113: ...gure 50 Measuring axial clearance A The axial clearance A of the rotor should always be measured before and after service work on the turbocharger Measure and note axial clearance A Product Axial clearance A mm A165 L 0 32 0 62 A170 L 0 33 0 63 A175 L 0 38 0 68 A180 L 0 41 0 73 A185 L 0 43 0 77 A190 L 0 45 0 80 Table 35 Admissible axial clearance A CAUTION Clearances outside the tolerance Serious ...

Page 114: ...ser Part number A165 L A170 L A175 L A180 L A185 L A190 L 77015 M5 6 Nm M6 10 Nm M8 25 Nm M8 25 Nm M10 45 Nm M10 45 Nm Table 36 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...

Page 115: ...sassembly and assembly Page 85 111 Copyright 2016 ABB All rights reserved HZTL4034_EN Revision F June 2016 Fitting the wall insert Figure 52 Positioning wall insert Carefully bring wall insert 77000 into vertical position with the lifting device 90190 ...

Page 116: ...2 Fit two guide studs 90320 in the upper area of the compressor casing 72000 3 Align arrow markings of wall insert 77000 and compressor casing to one another 4 Carefully move the wall insert with diffuser 79000 over the guide studs into the compres sor casing 5 Fit a screw 72011 as a safeguard 6 Change the position of the shackle 90195 with the lifting gear to P1 of the lifting device 90190 and re...

Page 117: ...itting the filter silencer with noise package 88 Figure 54 Fitting the filter silencer Part number A165 L A170 L A175 L A180 L A185 L A190 L 72004 M14 130 Nm M16 200 Nm M18 300 Nm M20 420 Nm M22 570 Nm M24 710 Nm Table 38 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 w...

Page 118: ...ensure that the individual sealing segments of the gasket 81301 and the gas ket 74042 are not damaged and that the contact surfaces are clean Figure 55 Fitting the filter silencer with noise package Part number A165 L A170 L A175 L A180 L A185 L A190 L 72004 M14 130 Nm M16 200 Nm M18 300 Nm M20 420 Nm M22 570 Nm M24 710 Nm 74043 M10 45 Nm M10 45Nm M10 45Nm M10 45Nm M10 45Nm M10 45 Nm Table 39 Tigh...

Page 119: ...ded stud of the compressor cas ing 72000 2 Attach the lifting gear to the front lug and rear eyelet of the filter silencer 81000 3 Position filter silencer on compressor casing 4 Fit nuts 72004 with washers 72003 and insulating discs 81302 and tighten 5 Fit insulation ring 81300 6 Fit air outlet silencer 74040 with gasket 74042 and secure with counter sunk screws 74043 Fit insulation as far as nec...

Page 120: ...00 L 8 Disassembly and assembly Page 90 111 Copyright 2016 ABB All rights reserved HZTL4034_EN Revision F June 2016 8 16 Table of tightening torques Figure 56 Overview of tightening torques Figure 57 Overview of speed sensor tightening torque ...

Page 121: ...400 M30 1900 M33 2570 63 1 72004 M14 130 M16 200 M18 300 M20 420 M22 570 M24 710 63a 72002 M14 40 M16 60 M18 80 M20 100 M22 120 M24 140 64 77015 M5 6 M6 10 M8 25 M8 25 M10 45 M10 45 65 56014 M10 35 M10 35 M10 35 M12 65 M12 65 M16 170 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 M27x2 320 M27x2 320 M27x2 320 Table 40 Overview of tightening to...

Page 123: ...s Dismantle filter silencer and lock rotor with locking device Fit cover plates to compressor outlet gas inlet and gas outlet casing of defective turbo charger Engines with bypass around the turbocharger Engines without bypass around the turbocharger Open bypass If the nozzle ring is removed not mandatory a higher engine load can be achieved Continue to operate engine in accordance with enginebuil...

Page 124: ...balance values if set screws balancing screws are loosened or unscrewed on the compressor wheel Before recommissioning of the turbocharger the compressor wheel must be balanced at an ABB Turbocharging Service Station Do not screw any set screws that have become unscrewed into the com pressor wheel again Balance the compressor wheel A locked rotor must be removed after emergency operation and check...

Page 125: ...able below for the tightening torque without the re taining nuts N If more than 3 drill holes in the hub of the compressor wheel are occupied by set screws the corresponding number must be unscrewed 6 Fit screw B2 refer to the table below for the tightening torque Product Tightening torques of screws B1 B2 Nm Thread A165 L 25 M8 A170 L 25 M8 A175 L 45 M10 A180 L 45 M10 A185 L 75 M12 A190 L 75 M12 ...

Page 126: ...sing must be ensured In this case additional washers 01 must be pro vided in accordance with the following table These washers 01 are not included in the ABB Turbo Systems scope of delivery Figure 59 Ensuring clamping of the cover ring Product h mm d1 mm d2 mm A165 L 3 5 4 0 13 20 A170 L 3 5 4 0 13 20 A175 L 4 0 5 0 17 28 A180 L 4 0 5 0 21 34 A185 L 4 5 6 0 21 34 A190 L 4 5 6 0 25 39 Table 44 Requ...

Page 127: ...operation Page 97 111 Copyright 2016 ABB All rights reserved HZTL4034_EN Revision F June 2016 9 3 4 Continuing to operate the engine Continue to operate engine in accordance with enginebuilder s instructions Do not exceed prescribed power reduction and maximum turbocharger speed ...

Page 128: ...ds Observe the speeds of the undamaged turbochargers Reduce the engine load if necessary 9 4 1 Blanking off the inlets and outlets The chapter is only applicable for engines with several turbochargers and joint air and exhaust gas receivers Close the lubricating oil supply to the turbocharger Blank off flange from compressor casing outlet gas inlet and gas outlet by the installation of cover plate...

Page 129: ...ating 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 protective equipment PPE according to the material ...

Page 130: ...tely The turbocharger has been 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 out of operation for up to 12 months subsection Preparations for mothballing If the turbocharger remains attached to the engine see section Taking out of operation for up to 12 months subsection Rot...

Page 131: ...afety 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 filte...

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Page 133: ...ts can be ordered from any ABB Turbocharging Service Station If different model variants are not taken into account in this document contact an ABB Turbocharging Service Station Required customer spare part set 97070 For the operations described in the Operation Manual the customer spare part set 97070 is required These parts are only available in the complete set Quantity Designation Part number ...

Page 134: ... Product description A100 L 12 Spare parts Page 104 111 Copyright 2016 ABB All rights reserved HZTL4034_EN Revision F June 2016 12 2 View of turbocharger with part numbers Figure 60 View of turbocharger with part numbers ...

Page 135: ...ot 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 customer spare part set O ring 79000 Diffuser 79020 in the customer spare part set ...

Page 136: ...t 2016 ABB All rights reserved HZTL4034_EN Revision F June 2016 12 3 View of cartridge group with part numbers Figure 61 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 137: ...l 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 42306 O ring 42307 O ring 423...

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Page 139: ...r casing 4 63 Fig 27 Fitting filter silencer casing 5 63 Fig 28 Fitting the bellows 64 Fig 29 Dismantling the filter silencer 65 Fig 30 Dismantling the filter silencer with noise package 66 Fig 31 Pressing off compressor casing 67 Fig 32 Moving out wall insert 68 Fig 33 Putting down wall insert 68 Fig 34 Putting down wall insert 69 Fig 35 Dismantling the diffuser 70 Fig 36 Measuring axial clearanc...

Page 140: ...e 110 111 Copyright 2016 ABB All rights reserved HZTL4034_EN Revision F June 2016 Fig 58 Locking the rotor 95 Fig 59 Ensuring clamping of the cover ring 96 Fig 60 View of turbocharger with part numbers 104 Fig 61 View of cartridge group with part numbers 106 ...

Page 141: ...tions during operation Exhaust gas temperature too high 53 Table 21 Malfunctions during operation Charge air pressure too low 53 Table 22 Malfunctions during operation Charge air pressure too high 54 Table 23 Surging of the turbocharger 54 Table 24 Malfunctions when stopping noises during run down 55 Table 25 Malfunctions when stopping run down time shortened 55 Table 26 Malfunctions of the speed ...

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