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ABB HT580635, Operation Manual

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ABB HT580635 Operation Manual Download Page 174

Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..

14  Taking out of operation at short notice / 14.2  Installing the replace-
ment turbocharger

© Copyright 2018 ABB. All rights reserved.

HZTL4032_EN

Revision H

July 2018

14.2

Installing the replacement turbocharger

To enable you to quickly put an engine back into operation after a turbocharger has sus-
tained damage, ABB Turbo Systems recommends having a replacement turbocharger or ap-
propriate spare parts available in storage. The defective turbocharger can be removed and
the replacement turbocharger installed within a short period of time.

u

Remove defective turbocharger (see chapter 

Removing and Installing 

→

10

).

u

Install replacement turbocharger (see chapter 

Removing and Installing 

→

10

).

u

Send the defective turbocharger to an ABB Turbocharging Service Station for inspection
and repair.

14.3

Installing the replacement cartridge group

14.4

Fitting the cover plate

u

Remove turbocharger (see chapter 

Removing and Installing 

→

10

).

¡

Gas outlet casing removed

u

Fit the turbine casing with the gas outlet casing into the gas pipe again.

u

Attach the cover plate (see following section).

¡

Gas outlet casing not removed

u

Fit the turbine casing into the gas pipe and on the gas outlet casing again.

u

Attach the cover plate (see following section).

Page 

144

 / 

161

Summary of Contents for HT580635

Page 1: ...arging Operation Manual A150 M66 HT580635 English Original Operation Manual Chapter Document ID 1 Introduction HZTL4005_EN_F 2 Safety HZTL4022_EN_E 3 Safety data sheet HT580635 4 Product description HZTL4032_EN_H ...

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: ... contents Copyright 2017 ABB All rights reserved HZTL4005_EN Revision F May 2017 Introduction 1 Introduction 2 1 1 Purpose of the manual 2 1 2 Symbols definitions 3 1 3 Storage of new turbochargers and spare parts 5 1 4 Contact information 7 ...

Page 4: ...explains the turbocharger and contains instructions for safe opera tion The Operation Manual is a complement to and expansion of existing national regulations for occupational safety accident prevention and environmental protection Target group The Operation Manual is aimed at engineers and trained mechanics responsible for the proper operation of the engine and for the turbocharger connected to i...

Page 5: ...n 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 Systems Offici...

Page 6: ...Meaning Pictogram Meaning Tighten with specified torque Affix Tighten over specified tighten ing 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 accord ance with specifications Dispose of in an environmentally compatible professional...

Page 7: ...ous in terms of the Ordinance on Hazardous Substances Nevertheless the following points must be observed when handling VCI u Observe information in material safety data sheet u Ensure proper space ventilation u Do not eat drink or store food at the workplace while working with VCI u Clean hands and face after working with VCI u For more information see www branopac com Wear safety gloves to protec...

Page 8: ... repackaged by an ABB Turbocharging Service Station u 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 Repl...

Page 9: ...ights reserved HZTL4005_EN Revision F May 2017 1 4 Contact information Contact information for the ABB Turbocharging Service Stations is available online u Scan the QR code to access our website ABB Turbo Systems Ltd Bruggerstrasse 71a CH 5401 Baden Switzerland www abb com turbocharging Page 7 7 ...

Page 10: ......

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

Page 12: ...e of insufficient compliance with safety instructions Are a consequence of insufficient or inappropriate performance of maintenance and in spection work The operating company is responsible for defining measures that regulate safe access to and safe handling of the turbocharger All instructions contained in this chapter must be observed for safe and trouble free opera tion of the turbocharger and ...

Page 13: ... mask to protect against Dusts Gases Safety helmet Ear protection Table 2 Personal protective equipment to be worn specific to the respective task 1 4 Definition of safety instructions WARNING Definition of Warning Non compliance or inaccurate compliance with working or operating in structions indicated by this symbol and the word WARNING can lead to seri ous injuries to personnel and even to fata...

Page 14: ...ure 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 informa tion 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 non i...

Page 15: ...ur bocharger or improper operation 1 6 Deflagration on gas engines ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar After a deflagration event ABB 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 i...

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

Page 17: ...agreed 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...

Page 18: ...above nMmax 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 description 1 9 Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging such as those...

Page 19: ...gainst mechanical hazards Wear safety helmet Fig 3 Attachment of loads on the crane hook Fig 4 Attachment angle If there are two or more suspension points the attachment angle of 45 must not be ex ceeded This prevents excessive loading due to diagonal pull u Before looping around the components of the turbocharger let them cool down max imum 80 C u Attach components of the turbocharger as describe...

Page 20: ...hecked periodically Suitable working materials and personal protective equipment must be kept in a perfect condition Only authorised personnel may remain in the vicinity of the turbocharger when the engine is running Competence of personnel The turbocharger must only be operated and serviced by trained and authorised personnel Basic mechanical training is a prerequisite Modifications to the turboc...

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

Page 22: ...oves 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 u Operate the turbocharger in compliance with the specifications u Secure the rotor aga...

Page 23: ...al installations u 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 u Visually inspect your working environment before starting...

Page 24: ...n and insulation can cause serious injuries to per sons or even fatal accidents u Only operate the turbocharger with burst protection fitted and insulation fitted in one of the following permitted variants Fig 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 AB...

Page 25: ...have received instruction or train ing Wear safety footwear to protect against mechanical hazard and risk of fall ing Wear protective clothing WARNING Risk of falling When working on the turbocharger there is a risk of falling u Do not climb onto the turbocharger or onto attached parts and do not use them as climbing aids u Use suitable climbing aids and working platforms for work above body heigh...

Page 26: ...y during disassembly assembly maintenance and repair u Observe the procedures for set up service and inspection work and the inspection inter vals u Inform the operating staff before starting any service or repair work Make sure the en gine is not started while work is being conducted on the turbocharger u Before taking off any cover or removing any guard from the turbocharger switch off the engin...

Page 27: ...ve previously received instruc tion or training Hazards due to operating materials and supplies Operating materials and supplies are substances required for the operation of the tur bocharger or for the performance of maintenance work Oils greases coolants detergents and solvents acids and similar substances can be classified as hazardous substances WARNING Handling operating materials and supplie...

Page 28: ... in the material safety data sheet for the operat ing materials and supplies u Comply with local legislation Hazards due to the handling of insulation materials WARNING Danger from insulation materials Dust or fibres from insulation materials can have adverse effects on the health or cause irritations Unsuitable and combustible insulation materials are a fire hazard u Only use suitable and non com...

Page 29: ...Operation Manual A150 M66 Safety data sheet Page 1 1 Safety data sheet Copyright 2018 ABB All rights reserved HT580635 August 2018 A150 M66 HT580635 A150 M66 HT580635 555 630 555 600 1200 12 50 50 2018 ...

Page 30: ......

Page 31: ...3 1 Oil supply 20 3 2 Inspection procedures 22 3 3 Commissioning after taking out of operation 24 4 Monitoring operation 25 4 1 Oil pressure oil temperature 25 4 2 Exhaust gas temperature before turbine 27 4 3 Turbocharger speed 28 5 Operation and service 31 5 1 Noise emission 31 5 2 Service work 33 5 3 Expected replacement intervals 36 5 4 Stopping the engine 38 6 Periodic maintenance work 39 6 1...

Page 32: ...stalling nozzle ring 92 9 12 Installing the cartridge group 93 9 13 Installing the compressor casing 96 9 14 Turning the cartridge group with compressor and turbine casing 98 9 15 Installing the gas outlet flange 99 9 16 Radial clearances N and R 100 9 17 Fitting the insulation 101 9 18 Installing the cartridge group with compressor and turbine casing 102 9 19 Installing the gas outlet casing 103 ...

Page 33: ... replacement turbocharger 144 14 3 Installing the replacement cartridge group 144 14 4 Fitting the cover plate 144 14 5 Cover plate drawing 146 15 Mothballing the turbocharger 148 15 1 Taking the engine out of operation for up to 12 months 148 15 2 Taking the engine out of operation for more than 12 months 149 16 Disposing of turbocharger components 150 17 Spare parts 151 17 1 Ordering spare parts...

Page 34: ...iptions of components that are not relevant for a specific turbocharger variant Please contact an ABB Turbocharging Service Station if you have any questions regarding a design variant see Contact information at www abb com turbocharging Accuracy of illustrations The illustrations in this document are general in nature and intended for ease of understand ing Differences in detail are therefore pos...

Page 35: ...eserved HZTL4032_EN Revision H July 2018 1 3 Related documents Chapter Document number Operation Manual 1 Introduction HZTL4005 Operation Manual 2 Safety HZTL4022 Operation Manual 3 Safety data sheet Serial number of the turbocharger Table 1 Related documents This chapter is only available in serialised operation manuals Page 5 161 ...

Page 36: ... 2018 1 4 Layout and function of the turbocharger Fig 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 6 161 ...

Page 37: ... to the engine cylinders The rotor runs in two radial plain bearings 06 which are located in the bearing casing 04 between the 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 ...

Page 38: ...arning plates are not present in the designated locations or not readable proceed as fol lows u Order new warning plates from ABB Turbocharging Service Stations u Remove any warning plates that have become unreadable u Clean and degrease the areas designated for the warning plates u Fit new warning plates and remove protective sheets Turbochargers supplied to the enginebuilder without insulation m...

Page 39: ...cations of the rating plates Copyright 2018 ABB All rights reserved HZTL4032_EN Revision H July 2018 1 6 Locations of the rating plates Fig 4 Locations of the rating plates One rating plate 01 each is attached on the left and the right side of the turbocharger bear ing casing Page 9 161 ...

Page 40: ...t must be used for removing and installing the tur bocharger The following weight specification applies to the heaviest variant possible De pending on the specification the weight specified on the rating plate may be lower than the standard value specified here Product Weights kg A150 M 1200 A155 M 1800 Table 2 Weights of turbocharger A150 M A155 M Fig 5 Suspension of complete turbocharger unit A ...

Page 41: ...rew connection 01 must not be loosened during disassembly The gas outlet casing 61001 can remain fitted in the exhaust gas pipe if the locking nuts are accessible Otherwise the complete turbocharger unit including gas outlet casing must be removed Fig 7 Removing the turbocharger u Secure the lifting gear to the turbocharger see illustration u If present Loosen and remove the compressor wheel cooli...

Page 42: ...g steps for loosening the pressure screws CAUTION Do not clean pressure screws The pressure screws are equipped with a permanent sliding layer that must not be removed Do neither clean nor lubricate the pressure screws In case of non compli ance it cannot be ensured that the necessary tension force is reached u Do not clean pressure screws u Do not lubricate pressure screws Fig 8 Loosening the cla...

Page 43: ... can result in serious personal injury u Place the turbocharger on a clean level support u Secure the turbocharger to prevent it from tipping over by using wooden beams and wedges and by taking the centre of gravity into account Fig 9 Turbocharger centre of gravity 01 Centre of gravity u Remove the turbocharger from the engine support u Remove and dispose of the O rings 42195 42200 u Set down and ...

Page 44: ..._EN Revision H July 2018 2 3 Installing the turbocharger 2 3 1 Inserting gaskets CAUTION Inserting the gaskets Gaskets that are forgotten damaged or improperly inserted will lead to oil leaks u Always use new gaskets and insert them carefully into the slot Fig 10 Inserting the gasket 01 Oil supply 02 Oil drain 42200 O ring 42201 Bearing casing 42202 O ring Page 14 161 ...

Page 45: ...the 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 u Screw the centering bush 42193 flush onto the threaded rod from below u Clean the surface of the bracket the bearing casing the centering bush and the centering holes...

Page 46: ...cket and position using the centering bushes 42193 located in the bracket 5 Check value x u If value x is not reached the turbocharger must be lifted up from the bracket and re aligned Step D Fixing the threaded rod in place in the bracket u Using the hexagon screw the threaded rod into the bracket up to value L u If value L is not reached or the threaded rod jams while being screwed in the thread...

Page 47: ...ensured that the necessary tension force is reached u Do not clean pressure screws u 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 u Make sure the pressure screws do not protrude in the direction of the thrust washer Fig 13 Preparing the clamping nut for the ti...

Page 48: ...g the turbocharger Copyright 2018 ABB All rights reserved HZTL4032_EN Revision H July 2018 Tightening pressure screws Fig 14 Tightening pressure screws Torque controlled tightening Product Fixing screw mm Tightening torques Nm A150 M30 45 A155 M36 85 Table 4 Pressure screw tightening torques Page 18 161 ...

Page 49: ...lder Version with compressor 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 u Make sure there is an uninterrupted supply of cooling air during opera tion Fig 16 Connecting the compressor cooling air intake u Remove the screw plug on the connection for the compressor wheel...

Page 50: ...ebuilder 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 u Switch on the oil pump u Build up oil pressure u Do not exceed a pre lubrication time of 2 minutes u Start the engine u Let the oil pump run until the pump driven by the engine generates sufficient pressure 3 1 3 Oil filtering Filt...

Page 51: ...TL4032_EN Revision H July 2018 3 1 5 Oil orifice in the bearing casing Fig 18 Oil orifice 01 Bearing casing 02 Oil orifice 03 Circlip With an oil inlet pressure of more than 3 bar of overpressure with engine under load up stream of the turbocharger the bearing casings are equipped with an orifice at the oil inlet as standard Page 21 161 ...

Page 52: ...ticles in the oil u For the initial commissioning phase and after all service work flush the complete lubricating system with warm oil u Use special running in filters when running in the engine and after all ser vice work on the lubricating system u Check that the oil filter is clean before commissioning u Check the oil pressure in the oil supply pipes Warning plates u Check whether warning plate...

Page 53: ...s for leaks 3 2 4 Checks when starting up the engine If present u Measure speed oil pressure and charging pressure at various engine performances u Measure the exhaust gas temperature before and after the turbine u Measure the air temperature before and after the compressor u Compare the measured values with the values of the acceptance report Different operat ing conditions indicate a malfunction...

Page 54: ... cooling u Remove the locking screw on the cooling air connection and fit the cooling air line General u Check the exhaust gas pipe before and after the turbine for combustion residues or wa ter residues and clean it Remove any foreign objects that may be present u Check and clean filter silencer or air supply line and remove any foreign objects that may be present u Put engine side oil circulatio...

Page 55: ...ne or property can result from a missing or insuf ficient lubricating oil supply u The lubricating oil pressure must be monitored during operation and the necessary pressure assured at the oil inlet Status for operation Pressure at oil inlet upstream of the turbocharger bar Overpressure Normal operation 2 0 poil 4 5 Engine start Cold oil admissible for a maximum of 15 minutes 8 0 Engine idling adm...

Page 56: ...the drain pipe as close to the turbocharger as possible Lubricating oil temperature at the inlet CAUTION Machine damage If the oil temperature at the oil inlet exceeds the admissible range this may lead to engine damage u Observe oil temperature at the oil inlet according to the following table Status for operation Oil temperature at the inlet Toil inlet Admissible 30 90 C Temporarily admissible 1...

Page 57: ... period of time outside of the admissible range ABB Turbo Systems recommends to have the turbocharger inspected by an ABB Tur bocharging Service Station 4 2 Exhaust gas temperature before turbine CAUTION Factors influencing replacement intervals Operation above the operating limits defined on the rating plate can shorten the recommended replacement intervals considerably u Measure exhaust gas temp...

Page 58: ...ocharger speed CAUTION Do not strain cables If you pull the speed measurement cables too hard contacts can be pulled out u Do not strain the speed measurement cables by pulling 4 3 2 Layout and overview Fig 19 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 Tacho...

Page 59: ...cannot be stopped it can continue to be driven at this reduced engine load or turbocharger speed u If a turbocharger surges continuously the engine performance must be reduced further u Measure the temperatures in the air lines and gas piping from and to the turbochargers and compare with normal values If clear deviations of temperature are found the nearest ABB Turbocharging Service Station has t...

Page 60: ... with a sealing lip and an O ring No additional gasket is required during assembly Fig 20 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 u Reduce the engine performance to idling and then stop the engine Pay attention to post lubrication Stopping the engine 38 u Switch off the lubricating oil supply to the turbocharger u Disco...

Page 61: ...red 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 tur bocharger 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 acoustic...

Page 62: ...on Copyright 2018 ABB All rights reserved HZTL4032_EN Revision H July 2018 Suggestion for noise insulation bellows Fig 21 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 32 161 ...

Page 63: ... or performed too late can cause excessive contamination wear and operating failures u 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 untimely machine damage even if the prescribed service intervals are ob ...

Page 64: ...k at 100 hours after commissioning u 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 u 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 o...

Page 65: ...ocharger 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 a...

Page 66: ...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 drastically 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 GAS MDO HFO Tu...

Page 67: ... due to the following influences Fuel quality and fuel treatment Load profile thermal cycling also number of starts stops emergency shutdowns oper ating 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 filte...

Page 68: ...r stopping the engine u Run the engine for 5 10 minutes at idling speed before stopping it u Observe the oil pressure specified for engine idling For oil cooled bearing casings post lubricate for 20 minutes if the turbine inlet temper ature 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 val...

Page 69: ...gine to be kept low while ensuring max imum fuel efficiency Maintenance inter val Maintenance work Operating status 24 72 h 1 Cleaning the compressor during operation 40 Engine load 50 85 50 200 h 1 Cleaning the turbine during operation 43 Engine load 20 40 guideline value Similar to the service interval usually every 8000 12000 h 2 Cleaning components mechanically 47 Engine stopped Table 10 Maint...

Page 70: ...ng the contaminated components cleaned mechanically by an ABB Turbocharging Service Station Periodic cleaning during operation does not replace the service work where the turbochar ger is completely dismantled and serviced by an ABB Turbocharging Service Station Cause and consequences of contamination The contamination of the compressor stage depends on the degree of purity of the air that is suck...

Page 71: ...ly after operating 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 u Never connect the water connection directly to a water pipe or a bigger metering container than the one specified by ABB Turbo Systems WARNING Danger ...

Page 72: ...g is removed by the mechanical action of the impacting droplets 6 2 5 Carrying out wet cleaning of the compressor Fig 22 Carrying out wet cleaning of compressor Engine load Filling amount of water pressure vessel dm3 Water temperature C Water injection period s 50 85 0 4 5 30 10 Table 11 Parameters for wet cleaning of compressor u Remove sealing plug 27005 u Fill container with 0 4 dm3 of pure wat...

Page 73: ...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 vana dium contents Operating states with incomplete combustion also increase the tendency to form deposits and must be avoided The combustion of heavy fuel oil HFO in diesel engines causes contamination of the tur bine stage Poor qua...

Page 74: ...s recommended This cleaning process is faster and reduces the risk of surging of the tur bocharger 6 3 4 Function and safety of wet cleaning CAUTION Corrosion and deposits when cleaning Salt water and cooling water treatment substances damage and adversely affect turbocharger parts u Never use salt water but only pure water for cleaning To clean the turbine stage during operation water is injected...

Page 75: ...er injection 350 430 C Stabilisation phase after TTE has been reached 10 minutes Stabilisation phase after turbine cleaning 10 minutes Water supply ensured Water temperature 5 30 C Water pressure overpressure compared to atmosphere pWT 1 5 bar 2 5 bar 2 External air supply recommended recommended External air pressure pPA relative to tur bine inlet pressure PTE PPA PTE 0 5 bar PPA PTE 1 bar Table ...

Page 76: ...he maximum temperature at the turbine inlet is not exceeded during cleaning Fig 24 Carrying out wet cleaning of turbines u Fulfil prerequisites u Ensure that the water supply 01 is guaranteed u Open the stop valve 02 and set the water volume flow VW with a flowmeter 03 see cleaning parameters u Close the stop valve 02 after 10 minutes u Wait for 10 minutes do not change the load during this stabil...

Page 77: ...is can lead to damage and corrosion on the components u Pay attention to the specifications in this chapter pertaining to mechan ical cleaning CAUTION Selection of cleaning tools Turbocharger components are sensitive and easily sustain mechanical dam age The use of needle descalers for example or other striking tools dam ages the components Depending on the specification nozzle rings or tur bine c...

Page 78: ...the filter ring if present u Remove filter ring 81265 u Clean filter ring 81265 as required or every 500 hours of operation and replace after the fifth cleaning process at the latest Contamination of the filter ring depends on the degree of purity of the sucked in air u Rinse the filter ring 81265 with water and mild detergent or in the case of heavy con tamination soak and carefully push through ...

Page 79: ...absorption segments 81136 must only be cleaned lightly with compressed air a soft brush or a moist cleaning cloth u Have any heavily contaminated absorption segments replaced by an ABB Turbocharging Service Station Fitting the filter silencer see Fig 25 Cleaning the filter silencer 48 u Insert the absorption segments 81136 into the sheet metal coverings 81137 u Bend the sheet metal coverings 81137...

Page 80: ...o the material safety data sheet u 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 accord ance with the description below Fig 26 Compressor end non rotating parts 72000 Compressor casing 77000 Wall insert 79000 Di...

Page 81: ...ating materials and supplies or con tact with them may be harmful to health u Do not breathe in these substances and avoid contact with the skin u Ensure proper ventilation u Observe the information in the material safety data sheet for the operat ing materials and supplies u Wear personal protective equipment PPE according to the material safety data sheet u Comply with local legislation Wear saf...

Page 82: ...ner to soften the contamination u Brush away the contamination or remove with a steam cleaner u Repeat the soaking and brushing process if necessary u Use clean water to remove all traces of solvent from parts u Dry components completely u Spray cleaned surfaces with penetrating oil Do not spray exterior surfaces of the tur bocharger u Dispose of dirty water and cleaning agents in accordance with ...

Page 83: ...end according to the following description 6 4 6 Cleaning the cartridge group on compressor end CAUTION Selection of the cleaning agent Cleaning agents which contain chlorine attack metals u Use only pH neutral cleaning agents which do not attack metals u Observe safety data sheet CAUTION Water and contamination in the cartridge group If water or contamination penetrates the cartridge group this c...

Page 84: ...e turbine are described in the following Fig 28 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 vertically in a container 02 with fluid u Place the container 02 inside a larger container 03 so that the overflowing fluid can be collected CAUTION Sele...

Page 85: ...bocharger and damage parts inside the cartridge group u Place the cartridge group on suitable supports 01 made of wood or metal u Observe dimension B for the supports 01 so that the cartridge group is not immersed too deeply u 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 ...

Page 86: ... deposits lead to rotor unbal ance This can result in bearing or turbocharger damage u Remove all traces of contamination from the turbine u After brushing off the dirt fill the container 02 with clean water and not with salt water u Immerse the turbine of the cartridge group in clean water so that any loose dirt comes off u Lift up the cartridge group and align it horizontally u Clamp the partiti...

Page 87: ...tact ABB Turbocharging Service Sta tion Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Contact enginebuilder Table 17 Malfunctions when starting Vibrations Rubbing of rotating parts Normal behaviour not a malfunction Turbocharger A slight amount of uniform wear at the circumference of the rotor components caused by slight local rubbing against adjacent components is pe...

Page 88: ...vice Station Engine Oil filter heavily contaminated Clean Oil pump in lubricating system defective Check replace Manometer displays incorrectly Replace manometer Table 19 Malfunctions during operation Lubricating oil pressure too low Speed reduces Possible causes Remedy Turbocharger Turbine and or nozzle ring severely con taminated Clean see chapter Periodic maintenance work 39 Rotor components or...

Page 89: ... cooling water 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 Turbocharger Manometer display not correct Replace manometer Supply pipe to manometer not sealed Repair leak F...

Page 90: ...amage A severely contaminated or corroded compressor wheel can reduce the com pressor wheel s fatigue endurance limit and result in the turbocharger being damaged u 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 39 O...

Page 91: ... u Have the cause clarified and remedied immediately by an ABB Turbochar ging Service Station u Have parts assessed for damage and if necessary replaced by an ABB Turbocharging Service Station Possible causes Remedy Turbocharger Filter silencer or diffuser contamin ated Clean see chapter Periodic maintenance work 39 Heavy contamination deposits in the turbine or in the nozzle ring Engine Protectiv...

Page 92: ...on Table 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 fol lowing table must be observed Possible causes Remedy Turbochar...

Page 93: ...refer to chapter Ordering spare parts 151 Replacing the speed sensor 30 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 amplifica tion of th...

Page 94: ...rotect against mechanical hazards WARNING Danger of burns Touching hot surfaces can cause severe burns u Do not touch hot surfaces u Wear heat resistant safety gloves u 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 de...

Page 95: ...wear u Damaged 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 set is available see chapter Spare parts 151 Oil orifice u When disassembling the turbocharger an oil orifice fitted in the oil inlet must not be re moved see also chapter Removing the cartridge group 85 Tightening torques for co...

Page 96: ...erms Suspension point Defined loading point on a component or an assembly blind hole thread eyelet lug Assembly device Devices that are fitted on the turbocharger in order to obtain a suspension point As sembly devices are specially constructed and designed for the defined use they are not commercially available products Use assembly devices only for the described applica tions Lifting gear Equipm...

Page 97: ...ich are not sup plied by ABB Turbo Systems Press off screws Product Thread Length Quantity A150 M M12 30 mm 3 or 6 A155 M M16 30 mm 3 or 6 Table 34 Press off screws Dismantling screw to be used for the optional 6 nozzle turbine cleaning component A dismantling screw 01 is required to dismantle and fit the cleaning nozzles which is not supplied by ABB Turbo Systems Dismantling screw Product Thread ...

Page 98: ...ith removed air inlet and gas outlet options the air suction branch or fil ter silencer as well as the gas outlet casing are removed from the turbocharger for the time being The cartridge group the turbine casing and the compressor casing can then be de tached from the engine and dismantled in an assembled state Reassembly is carried out in reverse order A prerequisite is that the interfaces betwe...

Page 99: ...rtridge group can be individually dismantled and fitted in the order shown in the illustration The turbine casing and optional gas outlet casing remain on the engine during the process In addition the nozzle ring can also be dismantled fitted with this concept not shown When employing the cartridge concept the turbine casing and the optional gas outlet cas ing remain on the engine Adequate support...

Page 100: ...er 90165 see Dismantling and fitting special tools for fastening strips 126 which in the event of limited accessibility can be used to facilitate the loosening of nuts and the application of tightening torques for the strip connection between the cartridge group and the turbine casing The spanner holder 90165 should only be used for loosening the nuts and applying tighten ing torques for the nuts ...

Page 101: ...Designation A150 kg A155 kg 01 Filter silencer 90 140 02 Radial air suction branch 24 40 03 Compressor casing with insulation 180 280 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 320 500 2 inlets 290 460 3 inlets 300 460 10 Gas outlet flange 35 65 11 Gas outlet casing with insulation 160 240 Table 36 Weights of ...

Page 102: ...iew 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 51007 with spanner holder 90165 M16 85 Nm M16 70 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 M1...

Page 103: ...tightening torques must be observed for the specified screw connections Position Part number A150 A155 16a 16b 1 M16 200 Nm M16 200 Nm 16b 2 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 38 Tightening torques for insulation 1 Tightening torque for attaching the insulation with integrated burst protection at the tur bine casing 2 Tightening torque for at...

Page 104: ...July 2018 9 Dismantling and fitting with removed air inlet and gas outlet 9 1 Removing air inlets Fig 35 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 82...

Page 105: ...k the casing position for assembly Variant without support Fig 36 Remove gas outlet casing without support 1 If present Remove waste gate pipe 2 Remove insulation ring 3 Fit swivel lifting eyes S to the gas outlet casing 61001 Attach lifting gear to swivel lift ing eye and secure to a crane hook 4 Loosen and remove nuts 51009 5 Remove the gas outlet casing 61001 set it down properly in an appropri...

Page 106: ...rved HZTL4032_EN Revision H July 2018 Variant with support Fig 37 Removing gas outlet casing with support 1 1 If present Remove waste gate pipe 2 Remove gas outlet casing insulation 3 Remove insulation ring 4 Remove fixing screws of support 61301 to bracket 5 Fit swivel lifting eyes S to the gas outlet casing 61001 Attach lifting gear to swivel lift ing eye and secure to a crane hook Page 76 161 ...

Page 107: ...gas outlet casing Copyright 2018 ABB All rights reserved HZTL4032_EN Revision H July 2018 Fig 38 Removing gas outlet casing with support 1 6 Loosen nuts 51009 and remove together with support 61301 7 Remove the gas outlet casing 61001 set it down properly in an appropriate place and secure it 8 Remove and dispose of the gasket 61002 Page 77 161 ...

Page 108: ...uly 2018 9 3 Removing the 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 out let casing The following variants are possible u Pressing off using 3 press off screws u Pressing off using 6 ...

Page 109: ...ry Treat the centering seat with rust remover through the press off threads and the clearance holes u Mark the casing position for assembly Fig 39 Dismantling the gas outlet flange Product Press off screws to be used strength 8 8 Tightening torque A150 3 x M12 x 30 65 Nm A155 3 x M16 x 30 150 Nm Table 39 3 press off screws not included in the ABB Turbo Systems scope of delivery 1 Evenly press off ...

Page 110: ...tlet flange does not cant u If necessary Treat the centering seat with rust remover through the press off threads and the clearance holes u Mark the casing position for assembly Fig 40 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 40 Press off screws gas outlet flange not included in the ABB Tu...

Page 111: ...July 2018 9 4 Removing the cartridge group with compressor and turbine casing Fig 41 Turbine cleaning nozzle 1 If present Loosen the turbine cleaning connection The cleaning nozzle 51301 must be replaced after each removal procedure If the clean ing nozzle is not to be replaced the screw connection 01 must not be loosened during disassembly Fig 42 Remove insulation 2 Remove the compressor casing i...

Page 112: ...g to the speed sensor 86505 and secure the rolled up cable on the turbocharger This protects the plug from being crushed 6 Attach lifting gear to the cartridge group and secure to a crane 7 Loosen clamping nut see Loosening the clamping nut 12 Fig 44 Set down the cartridge group with the compressor and turbine casing 8 Lift the cartridge group with the compressor and turbine casing 9 Fit two swive...

Page 113: ...the casing position for assembly Fig 45 Removing the compressor casing If the compressor casing cannot be loosened it can be pressed off against the turbine cas ing with the press off tool 90042 1 Loosen screws 72011 and remove together with fastening strips 72012 2 Attach swivel lifting eye S to the compressor casing and the lifting gear 3 Remove the compressor casing 72000 and turn it 180 4 Put ...

Page 114: ...the diffuser and the wall insert Fig 46 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 lift ing 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 R...

Page 115: ...ving the cartridge group u Mark the casing position for assembly Fig 47 Removing cartridge group 1 Position A150 M A155 M 01 150 Nm 150 Nm Table 41 Tightening torque 90012 01 1 Treat threads of studs 51006 with penetrating oil and leave to take effect 2 Loosen nuts 51007 and remove Verbus Ripp washers 51003 together with the fasten ing strips 51002 3 Fit the cross piece of the service support 9001...

Page 116: ...ridge group 2 If the cartridge group cannot be loosened the press off tool 90042 can be used 4 Secure the first set of lifting gear to the bearing casing 5 Secure the second set of lifting gear to the service support with a swivel lifting eye The length of the lifting gear must be selected in such a way that the compressor wheel is not touched when turning the cartridge group 6 Remove the cartridg...

Page 117: ... 9 6 Removing the cartridge group Copyright 2018 ABB All rights reserved HZTL4032_EN Revision H July 2018 Fig 49 Remove cartridge group 3 7 Place a suitable protective cover over the compressor wheel 8 Turn the cartridge group into the horizontal rotor axis 9 Remove lifting gear from service support and cross piece Page 87 161 ...

Page 118: ...on the service support Copyright 2018 ABB All rights reserved HZTL4032_EN Revision H July 2018 9 7 Installing the cartridge group on the service support Fig 50 Installing the cartridge group on the service support 1 Assemble the service support 90012 with longitudinal and cross pieces 2 Fit service support to cartridge group 3 Put down cartridge group Page 88 161 ...

Page 119: ... inlet and gas outlet 9 8 Removing the nozzle ring Copyright 2018 ABB All rights reserved HZTL4032_EN Revision H July 2018 9 8 Removing the nozzle ring Fig 51 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 89 161 ...

Page 120: ...0 12 0 22 0 72 1 28 A155 0 12 0 22 0 79 1 40 Table 42 Permissible clearances A and B 1 Move the rotor to and fro up to the stop In order to obtain a correct measurement elev ate 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 s...

Page 121: ...compression PD For the nozzle ring 56001 to be fixed during operation it must be clamped between the heat shield 42400 and the turbine casing 51000 Fig 53 Nozzle ring compression PD Product Compression PD mm A150 0 17 0 17 A155 0 17 0 17 Table 43 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 clea...

Page 122: ... HZTL4032_EN Revision H July 2018 9 11 Installing nozzle ring Fig 54 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 92 161 ...

Page 123: ... Installing the cartridge group Copyright 2018 ABB All rights reserved HZTL4032_EN Revision H July 2018 9 12 Installing the cartridge group Fig 55 Lifting the cartridge group and rotating it by 90 1 Fasten lifting gear to cartridge group and lift cartridge group 2 Remove service support 90012 3 Dismantle service support Page 93 161 ...

Page 124: ...n A150 M A155 M 01 150 Nm 150 Nm Table 44 Tightening torque 90012 01 4 Re fit the cross piece of the service support 90012 Observe the tightening torque 5 Place the protective cover over the compressor wheel 6 Secure the second set of lifting gear to the cross piece with a swivel lifting eye The length of the lifting gear must be selected in such a way that the compressor wheel is not touched 7 Tu...

Page 125: ...g the cartridge group Part number A150 M A155 M 51007 M16 175 Nm M16 175 Nm Table 45 Tightening torque 51007 8 Coat the threads of the studs 51006 with high temperature grease 9 Align casing position of cartridge group with marking and lower into the turbine casing 10 Remove lifting gear cross piece of service support 11 Install the fastening strips 51002 with Verbus Ripp washers 51003 and hexagon...

Page 126: ...diffuser Fig 58 Fitting the wall insert and the diffuser Part number A150 A155 79041 M6 8 Nm M6 8 Nm Table 46 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 atten tion to the positioning pin in the compressor casin...

Page 127: ...4032_EN Revision H July 2018 Installing the compressor casing Fig 59 Installing the compressor casing Part number A150 M A155 M 72011 M16 275 Nm M18 370 Nm Table 47 Tightening torque 72011 1 Fit a new O ring 42012 2 Thoroughly clean the fastening strips 72012 before assembly 3 Install the compressor casing 72000 4 Install the fastening strips 72012 with screws 72011 Observe the tightening torque P...

Page 128: ... Turning the cartridge group with compressor and turbine casing Fig 60 Turning the cartridge group with compressor and turbine casing 1 Attach second lifting gear to bearing casing and secure to the crane hook This lifting gear must be attached during the entire rotating procedure 2 Lift cartridge group with compressor and turbine casing with the first lifting gear and lower it with the second lif...

Page 129: ...July 2018 9 15 Installing the gas outlet flange Fig 61 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 ...

Page 130: ...no clearance The upper direc 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 tabl...

Page 131: ...r inlet and gas outlet 9 17 Fitting the insulation Copyright 2018 ABB All rights reserved HZTL4032_EN Revision H July 2018 9 17 Fitting the insulation Fig 63 Fitting the insulation u Fit the insulation according to the illustration Observe tightening torques see Table of tightening torques 72 Page 101 161 ...

Page 132: ...asing 1 Fit new O rings 42195 42200 2 Remove cover from oil inlet and outlet and carefully lower cartridge group with com pressor and turbine casing onto bracket Fig 65 Installing the cartridge group with compressor and turbine casing 3 Mount and tighten the clamping nut see Fastening the turbocharger with a clamping nut 17 4 Remove lifting gear from bearing casing 5 If present Remove the screw pl...

Page 133: ...Nm M16 200 Nm Table 49 Tightening torque 51009 1 Coat thread of bolts 51008 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 Place gas outlet casing at turbine casing 51000 Observe the marking 5 Fit hexagon nuts 51009 Observe the tightening torque 6 Fi...

Page 134: ...ng with support 1 Part number A150 M A155 M 51009 M16 200 Nm M16 200 Nm Table 50 Tightening torque 51009 1 Coat thread of bolts 51008 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 Place gas outlet casing at turbine casing 51000 Observe the marking 5...

Page 135: ...evision H July 2018 Fig 68 Fitting gas outlet casing with support 2 7 Fit the screws of the support Tighten in accordance with enginebuilder s specifications 8 Fit insulation ring Observe tightening torques see Table of tightening torques 72 9 Fit gas outlet casing insulation see Table of tightening torques 72 10 If present Attach waste gate pipe Tighten in accordance with enginebuilder s specific...

Page 136: ...stalling the air inlets Part number A150 A155 72051 M16 275 Nm M16 275 Nm Table 51 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 hexa...

Page 137: ...July 2018 10 Dismantling and fitting cartridge concept 10 1 Removing air inlets Fig 70 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 107 161 ...

Page 138: ...evision H July 2018 10 2 Removing the compressor casing u Mark the casing position for assembly Fig 71 Removing the compressor casing 1 Remove the compressor casing insulation 2 Fit swivel lifting eye S to the compressor casing 72000 Secure lifting gear to the swivel lifting eye 3 Loosen screws 72011 and remove together with fastening strips 72012 4 Remove the compressor casing 72000 Page 108 161 ...

Page 139: ...uly 2018 If the compressor casing cannot be loosened it can be pressed off against the turbine cas ing with the press off tool 90042 Fig 72 Pressing off compressor casing 1 Remove front turbine casing insulation 2 Press off compressor casing with press off tool 90042 Fig 73 Remove the diffuser 1 Remove and dispose of the O ring 42012 2 Set the compressor casing 72000 down on a suitable support Pag...

Page 140: ...er and the wall insert Fig 74 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 lift ing 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 ...

Page 141: ...ntling and fitting cartridge concept 10 3 Removing the cartridge group Copyright 2018 ABB All rights reserved HZTL4032_EN Revision H July 2018 10 3 Removing the cartridge group Removing the insulation Fig 75 Removing insulation sheets u Remove insulation sheets Page 111 161 ...

Page 142: ...readed rod dimension 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 nu...

Page 143: ...032_EN Revision H July 2018 Fig 77 Removing cartridge group 2 If the cartridge group cannot be loosened the press off tool 90042 can be used 1 Treat threads of studs 51006 with penetrating oil and leave to take effect 2 Loosen nuts 51007 and remove Verbus Ripp washers 51003 together with fastening strips 51002 3 Pull the cartridge group from the turbine casing and remove it Page 113 161 ...

Page 144: ... 2018 ABB All rights reserved HZTL4032_EN Revision H July 2018 Fig 78 Removing cartridge group 2 1 Remove the centering bush 42193 and the threaded rod 42191 along with the clamping nut 42201 2 Remove and dispose of the O rings 42195 42200 3 Attach the cartridge group to the service support 90012 4 If present Remove the metal C ring 51105 Page 114 161 ...

Page 145: ...g cartridge concept 10 4 Removing the nozzle ring Copyright 2018 ABB All rights reserved HZTL4032_EN Revision H July 2018 10 4 Removing the nozzle ring Fig 79 S_05180 1 Pull out the nozzle ring 56001 with the two extraction devices 90070 2 Remove the lamellar sealing ring 56005 Page 115 161 ...

Page 146: ... 0 72 1 28 A155 0 12 0 22 0 79 1 40 Table 53 Permissible clearances A and B 1 Move the rotor to and fro up to the stop In order to obtain a correct measurement elev ate 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 ...

Page 147: ...ation it must be clamped between the heat shield 42400 and the turbine casing 51000 Fig 81 Nozzle ring compression PD Product Compression PD mm A150 0 17 0 17 A155 0 17 0 17 Table 54 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 u If the calculated valu...

Page 148: ...EN Revision H July 2018 10 7 Installing nozzle ring Fig 82 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 118 161 ...

Page 149: ... out of the service support 90012 4 Fit new O rings 42195 42200 5 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 onto the expansion bush and with the clamp ing nut screwed on guide the threaded rod through the washer expansion bush and bearing casing 6 Screw the centering bush 42193 flush onto the...

Page 150: ...he hole in the bracket into which the centering bush 42193 is inser ted 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 Screw clamping nut 42201 upwards to end of threaded rod and insert the centering bush 42193 into the hole Check dimension X if dimension ...

Page 151: ...ig 85 Fitting the wall insert and the diffuser Part number A150 A155 79041 M6 8 Nm M6 8 Nm Table 57 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 atten tion to the positioning pin in the compressor casing 4 Fit th...

Page 152: ... Revision H July 2018 Installing the compressor casing Fig 86 Installing the compressor casing Part number A150 A155 72011 M16 275 Nm M18 370 Nm Table 58 Tightening torque 72011 u Thoroughly clean the fastening strips 72012 before assembly 1 Fit a new O ring 42012 2 Install the compressor casing 72000 3 Install the fastening strips 72012 with screws 72011 Observe the tightening torque Page 122 161...

Page 153: ...1 into the gap such that there is no clearance The upper direc 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 ...

Page 154: ...dge concept 10 11 Fitting the insula tion Copyright 2018 ABB All rights reserved HZTL4032_EN Revision H July 2018 10 11 Fitting the insulation Fig 88 Fitting the insulation u Fit the insulation according to the illustration Observe tightening torques see Table of tightening torques 72 Page 124 161 ...

Page 155: ... the air inlets Part number A150 A155 72051 M16 275 Nm M16 275 Nm Table 60 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...

Page 156: ...stems offers optional special tools which in the event of limited accessibility can be used to facilitate the loosening of nuts and the application of tightening torques for the strip connection between the cartridge group and the turbine casing The spanner holder 90165 should only be used for loosening the nuts and applying tighten ing torques for the nuts at the position shown Other screws or nu...

Page 157: ...ecial tools 90160 Fig 90 Special tools Part number Description Quantity 90160 Special tools complete 1 90161 Bag 1 90165 Spanner holder 1 90166 Spanner holder 1 Table 61 Special tools 90160 Customer tool not included in the ABB Turbo Systems scope of delivery Fig 91 Client tool Position Description Quantity 01 Collection tub 500x400x30mm 1 02 Torque spanner 40 200 Nm with plug connection for holdi...

Page 158: ... M Extended special tools 90160 Fig 92 Special tools Part number Description Quantity 90160 Special tools complete 1 90161 Bag 1 90162 Locking device 1 90163 Clamping device 1 90164 Tool disassembly segment 1 90165 Spanner holder 2 Table 63 Special tools 90160 Customer tool not included in the ABB Turbo Systems scope of delivery Fig 93 Client tool Position Description Quantity 01 Universal pliers ...

Page 159: ...ng the spanner holder 90165 3 Loosen the two nuts on the other side by using the spanner holder 90166 The cartridge group is fitted at this point in time To enable a clear representation of the work step the cartridge group is not illustrated in work step 4 Fig 95 Removing the fastening strips 4 Remove the nuts 51007 with spanner holder 90165 90166 and attached torque span ner 02 Remove washers 51...

Page 160: ...1 Fit the nuts 51007 of the upper fastening strips 51002 illustrated and tighten with a torque spanner 02 without a spanner holder Observe the tightening torque Fig 97 Fitting the bottom fastening strip 2 Position the collection tub 01 to catch any fixing elements if they fall 3 Tighten the two nuts on one side by using the spanner holder 90165 4 Tighten the two nuts on the other side by using the...

Page 161: ...yright 2018 ABB All rights reserved HZTL4032_EN Revision H July 2018 Fig 98 Fitting the bottom fastening strip Part number A150 M A155 M 51007 with spanner holder M16 85 Nm M16 70 Nm Table 66 Tightening torque 51007 with spanner holder 5 Fit the nuts 51007 with spanner holder 90165 90166 and attached torque spanner 02 Observe the tightening torque Page 131 161 ...

Page 162: ...hts reserved HZTL4032_EN Revision H July 2018 11 1 1 A155 M Fit fastening strips with extended special tool Fig 99 Fitting the cartridge group Part number A155 M 51007 M16 175 Nm Table 67 Tightening torque 51007 1 Fit the nuts 51007 of the upper fastening strips 51002 illustrated and tighten with a torque spanner 02 without a spanner holder Observe the tightening torque Page 132 161 ...

Page 163: ...images so that all work steps are visually clear Fig 100 Positioning the fastening strip 2 Position fastening strip 51002 in the tool disassembly segment 90164 3 Clamp the strips A of the tool disassembly segment slightly using the universal pliers 03 to fix the fastening strip 4 Position the fastening strip with the segment disassembly tool onto the set screws 5 Push the fastening strip with the ...

Page 164: ...ing strips 11 1 Ap plication special tools Copyright 2018 ABB All rights reserved HZTL4032_EN Revision H July 2018 Fig 101 Clamping device 7 Fix the washer 51003 with clamping device 90163 and check to ensure it is properly seated 8 Position the washer 51003 on the set screw 9 Remove the clamping device Page 134 161 ...

Page 165: ...orque 51007 with spanner holder 10 Screw the nut 51007 loosely onto the locking device 90162 11 First position the cord end in the direction of the axis before winding up 12 Wind up the cord 7 10 times around the nut and over the cord end 13 Position the locking device 90162 with attached nut 51007 exactly onto the threaded stud and press on 14 Fit the nut 51007 onto the set screw by pulling the c...

Page 166: ...lling 6 nozzle turbine cleaning component optional 12 1 Disassembly The following illustration shows the initial situation before the 6 nozzle turbine cleaning component is dismantled Fig 103 Initial situation u Before disassembly mark the positions of the elbows 51311 Fig 104 Disassembly of the elbows 1 Just loosen the union nuts 51316 of the elbows 51311 Do not remove them yet 2 Just loosen the ...

Page 167: ...nent op tional 12 1 Disassembly Copyright 2018 ABB All rights reserved HZTL4032_EN Revision H July 2018 Fig 105 Disassembly of the elbows u Remove the elbows 51311 from the connecting pieces 51313 in the specified order 01 02 03 04 05 Fig 106 Pipe disassembly 1 Undo union nuts 51316 of pipe 51312 2 Remove pipe Page 137 161 ...

Page 168: ...sion H July 2018 Fig 107 Disassembly of the connecting pieces 1 Unscrew hexagon head screws 51314 from connecting pieces 51313 2 Remove gaskets 51302 3 Remove connecting pieces 4 Remove gaskets from holes Fig 108 Disassembly of the cleaning nozzle u Remove cleaning nozzles 51301 with screw 01 in accordance with the following table Position A150 M A155 M 01 M8x40 M10x50 Table 69 Dismantling screw P...

Page 169: ...ismantling screw 1 Screw the screw 01 into the cleaning nozzle 51301 as far as it will go 2 Insert the cleaning nozzle with screw as far as it will go 3 Rotate the cleaning nozzle clockwise until the cleaning nozzle lowers further and is thus correctly positioned u Remove the screw 01 ensuring that the cleaning nozzle remains in position Fig 110 Assembly of the connecting pieces 1 Position gaskets...

Page 170: ...t thread and contact surfaces of cutting ring with high temperature grease 2 Position pipe 51312 3 Position union nuts 51316 of pipe on connecting piece 51313 and screw in fitting 51305 and tighten by hand only Fig 112 Assembly of elbows 1 u Coat thread and contact surfaces of cutting ring with high temperature grease u Screw the union nuts 51316 of the elbows 51311 onto the connecting pieces 5131...

Page 171: ...ssembly Copyright 2018 ABB All rights reserved HZTL4032_EN Revision H July 2018 Fig 113 Assembly of elbows 2 Part number A150 M A155 M 51314 80 Nm 100 Nm 51316 70 Nm 90 Nm Table 71 Tightening torque 51314 51316 1 Tighten hexagon head screws 51314 to tightening torque 2 Tighten union nuts 51316 of elbows 51311 to tightening torque Page 141 161 ...

Page 172: ...ved HZTL4032_EN Revision H July 2018 13 Fitting the cleaning nozzles with multi inlet turbine casings Fig 114 Fit the cleaning nozzles 1 The designation P on the turbine casing must correspond with the designation P on the cleaning nozzle 2 The edges for the defined installation position in the turbine casing and at the cleaning nozzle must correspond Page 142 161 ...

Page 173: ...onmentally 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 u Follow the directives of the enginebuilder If the engine has to be operated again as quickly as possible following a turbocharger de f...

Page 174: ...rbocharger installed within a short period of time u Remove defective turbocharger see chapter Removing and Installing 10 u Install replacement turbocharger see chapter Removing and Installing 10 u Send the defective turbocharger to an ABB Turbocharging Service Station for inspection and repair 14 3 Installing the replacement cartridge group 14 4 Fitting the cover plate u Remove turbocharger see c...

Page 175: ...cover plate u 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 Coat the threads of the studs 51006 with high temperature grease 4 Fasten cover plate 01 to turbine casing 51000 with fastening strips 51002 Verbus Ripp washers 51003 and nuts 51007 and ...

Page 176: ...not included 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 Fig 116 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 M...

Page 177: ... of operation at short notice 14 5 Cover plate drawing Copyright 2018 ABB All rights reserved HZTL4032_EN Revision H July 2018 Fig 117 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 73 Cover plate dimensions mm Page 147 161 ...

Page 178: ...nd the bearing parts are largely protected against corrosion Preparations for mothballing WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or con tact with them may be harmful to health u Do not breathe in these substances and avoid contact with the skin u Ensure proper ventilation u Observe the information in the material safety ...

Page 179: ...earing parts are dismantled by an ABB Turbocharging Service Station and stored separately The turbocharger is completely removed either as a whole unit or in individual parts For the measures always necessary for preparing the turbocharger parts for mothballing see section Taking the engine out of operation for up to 12 months subsection Preparations for mothballing If the turbocharger remains att...

Page 180: ...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 filter comp...

Page 181: ...ts are not taken into account in this document contact an ABB Turbocharging Service Station u Dispose of placed and unusable parts in an environmentally friendly and professional manner in accordance with the local regulations u Dispose of the packaging of new parts in an environmentally friendly and professional manner in accordance with the local regulations 17 2 Required customer spare part set...

Page 182: ...ine cleaning The customer spare part set 97151 is required for replacing the turbine cleaning nozzles as described in the Operation Manual These parts are only available in the complete set Part number Designation Quantity 51301 in the customer spare part set Cleaning nozzle 6 51302 in the customer spare part set Gasket 12 51314 in the customer spare part set Hexagon head screw 6 Table 75 Customer...

Page 183: ...description A150 M56 66 57 67 A155 M 17 Spare parts 17 3 Required customer spare part set 97151 for 6 nozzle turbine cleaning Copyright 2018 ABB All rights reserved HZTL4032_EN Revision H July 2018 17 3 1 1 Note page Page 153 161 ...

Page 184: ... turbocharger with part numbers Copyright 2018 ABB All rights reserved HZTL4032_EN Revision H July 2018 17 4 View of turbocharger with part numbers Fig 118 Overview of part numbers Depending on the specification of the turbocharger only available in customer spare part set 97070 Page 154 161 ...

Page 185: ...tion 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 insert 77005 in customer spare part set O ring 790...

Page 186: ...ghts reserved HZTL4032_EN Revision H July 2018 17 5 View of turbine cleaning device 17 5 1 One cleaning nozzle per turbine inlet Fig 119 Overview of part numbers Part number Designation 51301 1 inlet 1 cleaning nozzle 2 inlets 2 cleaning nozzles 3 inlets 3 cleaning nozzles 51302 Gasket 51303 Screw plug Table 77 Spare parts list Page 156 161 ...

Page 187: ...only available in customer spare part set 97151 Part number Designation 51301 in the customer spare part set Cleaning nozzle 51302 in the customer spare part set Gasket 51303 Screw plug 51304 Flange 51305 Screw in fitting 51308 Stud 51309 Expansion sleeve 51310 Hexagon head screw 51311 Elbow 51312 Pipe 51313 Connecting piece 51314 in the customer spare part set Hexagon head screw 51316 Union nut 5...

Page 188: ...28 Soaking the turbine end 54 Fig 29 Removing the cartridge group with com pressor and turbine casing 68 Fig 30 Cartridge concept 69 Fig 31 Optional spanner holder 70 Fig 32 Weights of assemblies 71 Fig 33 Overview of tightening torques 72 Fig 34 Tightening torques for insulation 73 Fig 35 Removing the air inlets 74 Fig 36 Remove gas outlet casing without support 75 Fig 37 Removing gas outlet casi...

Page 189: ...group 1 119 Fig 84 Installing the cartridge group 2 120 Fig 85 Fitting the wall insert and the diffuser 121 Fig 86 Installing the compressor casing 122 Fig 87 Measuring clearances N and R 123 Fig 88 Fitting the insulation 124 Fig 89 Installing the air inlets 125 Fig 90 Special tools 127 Fig 91 Client tool 127 Fig 92 Special tools 128 Fig 93 Client tool 128 Fig 94 Positioning the collection tub 129...

Page 190: ...h 59 Table 23 Malfunctions during operation Charge air pressure too low 59 Table 24 Malfunctions during operation Charge air pressure too high 60 Table 25 Malfunctions during operation Engine performance losses 60 Table 26 Malfunction Turbocharger pumping 61 Table 27 Malfunction Sporadic surge blows 61 Table 28 Malfunctions when stopping Runout noises 62 Table 29 Malfunctions when stopping Runout ...

Page 191: ...ools 90160 128 Table 64 Client tool 128 Table 65 Tightening torque 51007 130 Table 66 Tightening torque 51007 with spanner holder 131 Table 67 Tightening torque 51007 132 Table 68 Tightening torque 51007 with spanner holder 135 Table 69 Dismantling screw 138 Table 70 Dismantling screw 139 Table 71 Tightening torque 51314 51316 141 Table 72 Cover plate dimensions mm 146 Table 73 Cover plate dimensi...

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