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Page 1: ... Turbocharging Operation Manual A155 M66 HT597611 English Original Operation Manual Chapter Document ID 1 Introduction HZTL4005_EN_G 2 Safety HZTL4022_EN_E 3 Safety data sheet HT597611 4 Product description HZTL4032_EN_P ...

Page 2: ...als and the corresponding operating limits in chapter 3 are jointly defined with the enginebuilder This information is specific to the product Non observance of the recommended replacement intervals and the operating limits increases the risk of unpre dictable component failures ...

Page 3: ...of contents Copyright 2020 ABB All rights reserved HZTL4005_EN Rev G March 2020 Introduction 1 Introduction 2 1 1 Purpose of the manual 2 1 2 Symbols definitions 3 1 3 Storage of new turbochargers and spare parts 5 1 4 Contact information 7 ...

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

Page 5: ... the work Definition of mandatory signs Mandatory signs show the protective equipment to be worn for a task The mandatory signs are described in chapter Safety and must be complied with Definition of Caution Warning Caution and warning signs are described in chapter Safety ABB Turbocharging ABB Switzerland Ltd Turbocharging is identified as ABB Turbocharging or as ABB Turbo Sys tems in this docume...

Page 6: ...ictogram Meaning Tighten with specified torque Tighten over specified tightening angle Hand tight tighten without tools Oil Apply screw locking paste e g Loctite Apply high temperature grease Apply other paste in accordance with specifications Oil free grease free and dry Affix Measure Note Visually inspect Please note text for numbered work step See document Dispose of in an environmentally compa...

Page 7: ... the sense of the Hazardous Substances Ordinance Nevertheless the following points are to be observed when handling VCIs u Observe specifications in the safety data sheet u Ensure good room ventilation u Do not eat drink or keep food at the workplace while working with VCIs u Clean hands and face after working with VCIs u For further information refer to www branopac com Wear safety gloves to prot...

Page 8: ... the turbocharger must be inspected by an ABB Turbocharging Service Station and repacked u Inspect the package for damage If the package is damaged the turbocharger must be in spected by an ABB Turbocharging Service Station and repacked After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station Inspect the components Replace the desiccant agent Repackage...

Page 9: ...s reserved HZTL4005_EN Rev G March 2020 1 4 Contact information Contact information for the ABB Turbocharging Service Stations is available online u Scan the QR code to access our website ABB Switzerland Ltd Turbocharging Bruggerstrasse 71a CH 5401 Baden Switzerland www abb com turbocharging Page 7 7 ...

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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: ...on Manual A155 M66 Safety data sheet Page 1 1 Safety data sheet Copyright 2020 ABB All rights reserved HT597611 September 2020 A155 M66 HT597611 A155 M66 HT597611 466 650 439 620 HZTL53369H 1800 12 50 50 2020 ...

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Page 31: ... 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 Foreword to maintena...

Page 32: ...5 9 11 Installing nozzle ring 96 9 12 Installing the cartridge group 97 9 13 Installing the compressor casing 100 9 14 Turning the cartridge group with compressor and turbine casing 102 9 15 Installing the gas outlet flange 103 9 16 Radial clearances N and R 104 9 17 Fitting the insulation 105 9 18 Installing the cartridge group with compressor and turbine casing 106 9 19 Installing the gas outlet...

Page 33: ...ng the replacement turbocharger 151 14 3 Installing the replacement cartridge group 151 14 4 Fitting the cover plate 152 14 5 Cover plate drawing 153 15 Mothballing the turbocharger 155 15 1 Taking the engine out of operation for up to 12 months 155 15 2 Taking the engine out of operation for more than 12 months 156 16 Disposing of turbocharger components 157 17 Spare parts 158 17 1 Ordering spare...

Page 34: ...tions 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 possi...

Page 35: ... reserved HZTL4032_EN Rev P March 2020 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 5 171 ...

Page 36: ...020 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 6 171 ...

Page 37: ...o 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 de...

Page 38: ...ning 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 mus...

Page 39: ...Locations of the rating plates Copyright 2020 ABB All rights reserved HZTL4032_EN Rev P March 2020 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 9 171 ...

Page 40: ... be used for transporting the turbocharger The weight specified below applies to the heaviest variant possible Depending on the specifica tion the weight specified on the rating plate may be lower than the standard value specified here Fig 5 Suspension of complete turbocharger unit A Complete turbocharger unit without gas outlet casing B Complete turbocharger unit with gas outlet casing Product We...

Page 41: ...w 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 cooling...

Page 42: ...TION Do not clean pressure screws The pressure screws are equipped with a permanent sliding layer that must not be removed In case of non compliance it cannot be ensured that the necessary tension force is reached u Do not clean pressure screws u Do not lubricate pressure screws If a screw jams the previously loosened screw must be tightened again a little Fig 8 Loosening the clamping nut 1 Workin...

Page 43: ...an 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 se...

Page 44: ...32_EN Rev P March 2020 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 14 171 ...

Page 45: ...e top 3 Place the thrust washer 01 of the clamping nut on the expansion bush and with the clamping nut screwed on guide the threaded rod through the thrust washer expansion bush and bearing casing Step B Preparing the positioning 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 i...

Page 46: ...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 threaded rod mu...

Page 47: ...sured 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 tigh...

Page 48: ... Torque controlled tightening of the pressure screws 1 Screw in pressure screws crosswise by hand until reaching the stop 2 Tighten pressure screws crosswise to 50 of the tightening torque specified in the table 3 Tighten pressure screws crosswise to 100 of the tightening torque specified in the table 4 Work in a circle to tighten all pressure screws to 100 of the tightening torque specified in th...

Page 49: ...er 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 c...

Page 50: ...uilder s specifications regarding the selection of lubricating oil and the oil change intervals 3 1 2 Pre lubrication Pre lubrication must be carried out as follows 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 Filter...

Page 51: ...HZTL4032_EN Rev P March 2020 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 21 171 ...

Page 52: ...cles 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 plates ...

Page 53: ...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 s...

Page 54: ... wheel 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 circ...

Page 55: ...r 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 admissible for a maximum of 1 hour 0 5 poil 2 5 Pre lubrication and post lubrication engine stopped 0 5 poil 1 0 Warning signal n 0 5 x nBmax 1 25 Alarm signal Not admissible Stop the engine immedi ately 0 6 Tab...

Page 56: ...ble do not start engine before start preheat oil 30 C Table 6 Lubricating oil temperature at the inlet Lubricating oil temperature at the outlet The oil temperature at the outlet is mainly dependant on Lubricating oil temperature and pressure at the oil inlet Engine load and turbocharger speed Exhaust gas temperature The maximum admissible oil temperature at the outlet is listed in the following t...

Page 57: ...ing replacement intervals Operation above the operating limits defined on the rating plate can shorten the recommended replacement intervals considerably u Measure exhaust gas temperature upstream of turbine u Comply with operating limits on rating plate u Definition and explanations concerning rating plate refer to chapter 2 of Operation Manual Safety u Operating limits refer to chapter 3 of Oper...

Page 58: ...harger 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 Tachome...

Page 59: ...nnot 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 to ...

Page 60: ...ith 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 Disconn...

Page 61: ...d 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 acoustical...

Page 62: ...sion Copyright 2020 ABB All rights reserved HZTL4032_EN Rev P March 2020 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 32 171 ...

Page 63: ...er that is omitted or performed too late can cause excessive contamination wear and operating failures u Carry out the service work at the specified time intervals CAUTION Specific service interval Exceptional stresses such as a high number of starts and stops harsh envir onmental conditions poor fuel quality or high system vibrations can lead to untimely machine damage even if the prescribed serv...

Page 64: ...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 16000 ope...

Page 65: ...harger 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 air...

Page 66: ...or 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 reduce 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 Turb...

Page 67: ...ue 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 filteri...

Page 68: ...ore stopping it u Observe the oil pressure specified for engine idling see Table 5 Lubricating oil pressure at oil inlet before turbocharger 25 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 value...

Page 69: ...ing 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 According to rating plate 2 Cleaning components mechanically 47 Engine stopped 12000 h Uncoupled filter silencer A155 M Changing the absorption element 57 En...

Page 70: ... Tur bocharging recommends mechanical cleaning of the contaminated components Periodic cleaning during operation is not a substitute for the service work during which the turbocharger is completely dismantled and cleaned Cause and consequences of contamination The contamination of the compressor stage depends on the degree of purity of the air that is sucked in Deposits can form in the flow channe...

Page 71: ...fter 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 Turbocharging WARNING Danger due ...

Page 72: ...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 water...

Page 73: ...leaned Cause and consequences of contamination ABB Turbocharging recommends the use of fuels with low ash sulphur sodium and vana dium contents The combustion of heavy fuel oil HFO in diesel engines causes contamination of the tur bine stage Poor quality fuel in conjunction with high exhaust gas temperatures can lead to extremely hard deposits on turbine components Operating states with incomplete...

Page 74: ...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 b...

Page 75: ...injection 350 430 C Stabilisation phase after TTE has been reached 10 minutes Stabilisation phase after turbine clean ing 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 12...

Page 76: ... 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 stabilis...

Page 77: ... 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 cas...

Page 78: ...e 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 Ri...

Page 79: ...sorption 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 b...

Page 80: ...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 Diff...

Page 81: ...ing 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 safet...

Page 82: ...r 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 th...

Page 83: ...d 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 can...

Page 84: ...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 Select...

Page 85: ...charger 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 tr...

Page 86: ...eposits 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 partition...

Page 87: ...lement 81148 in uncoupled filter silencers must be replaced every 12000 hours of operation Disassembling the absorption element Fig 29 Disassembling the absorption element 1 Remove the filter silencer see Fig 41 Removing the uncoupled filter silencer 78 2 Dismantle the hexagon head screws 81152 with washers 81153 and mounting plate 81149 3 Remove the socket screws 81154 roll pins 81151 flanges 811...

Page 88: ...orption element 81148 and flanges 81145 81146 with roll pins 81151 and socket screws 81154 Tighten socket screws 81154 crosswise Observe the tightening torque 2 Check value X 15 mm 0 1 mm along the circumference at four points 0 90 180 and 270 If value X is not satisfied unscrew the socket screws 81154 and repeat step one 3 Fit the mounting plate 81149 with washers 81153 and hexagon head screws 81...

Page 89: ...act ABB Turbocharging Service Station Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Contact enginebuilder Table 18 Malfunctions when starting Vibrations Rubbing of rotating parts Normal behaviour not a malfunction Turbochar ger A slight amount of uniform wear at the circumference of the rotor components caused by slight local rubbing against adjacent components is per...

Page 90: ... Station Engine Oil filter heavily contaminated Clean Oil pump in lubricating system defect ive Check replace Manometer displays incorrectly Replace manometer Table 20 Malfunctions during operation Lubricating oil pressure too low Speed reduces Possible causes Remedy Turbochar ger Turbine and or nozzle ring severely con taminated Clean see chapter Periodic mainten ance work 39 Rotor components or ...

Page 91: ...ooling water too high Check clean cooling system Insufficient ventilation Improve ventilation Table 23 Malfunctions during operation Exhaust gas temperature too high Charge air pressure too low Engine performance and engine speed unchanged suction condition normal Possible causes Remedy Turbochar ger Manometer display not correct Replace manometer Supply pipe to manometer not sealed Repair leak Fi...

Page 92: ...e 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 Turbochar ger Compressor components severely con taminated by the ventilation gases that have been fed in Clean see chapter Periodic mainten ance work 39 Opt...

Page 93: ...ave 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 mainten ance work 39 Heavy contamination deposits in the turbine or in the nozzle ring Engine Protective g...

Page 94: ... Table 29 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 g...

Page 95: ...er to chapter Ordering spare parts 158 Replacing the speed sensor 30 Table 31 Malfunction of the speed measurement system No signal or poor signal amplitude Measured speed too high Possible causes Remedy Turbochar ger Sensor tip contaminated since it is magnetic and can attract metallic particles This reduces the distance to the signal emitting sealing disc which can lead to ampli fication of the ...

Page 96: ...arger may have sharp edges There is a risk of a cutting injury u Wear safety gloves against mechanical risks when conducting assembly and disassembly work Wear safety gloves to protect against mechanical hazards CAUTION Further work This Operation Manual may be used to carry out only the work described in it Further work that is carried out in an incorrect way can lead to serious damage to the mac...

Page 97: ...uaranteed by the tool list This list is enclosed with the tool set WARNING Servicing the tools The tools must be checked for damage before and after use u Visually inspect for corrosion cracks deformation and wear u Damaged tools must no longer be used and must be replaced Swivel lifting eyes Swivel lifting eyes are required for the safe lifting of loads which are not supplied by ABB Fig 31 Swivel...

Page 98: ...ews Product Thread Length Quantity A150 M12 30 mm 3 or 6 A155 M16 30 mm 3 or 6 Table 35 Press off screws Dismantling screw 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 Fig 33 Dismantling screw Product Thread Length mm Quantity A150 M M8 40 1 A155 M M10 50 1 Table 36 Dismantling screw P...

Page 99: ...hment of loads on the crane hook u People must not stand beneath suspended loads Wear safety gloves to protect against mechanical hazards Wear safety helmet Definition of terms Suspension point Defined loading point on a component or an assembly blind hole thread eyelet lug Assembly device Devices that are fitted on the turbocharger in order to obtain a suspension point As sembly devices are speci...

Page 100: ...h 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 between...

Page 101: ...ridge 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 o...

Page 102: ...see Dismantling and fitting special tools for fastening strips 133 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 po...

Page 103: ...signation 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 37 Weights of as...

Page 104: ... M 8 Dismantling and fitting general 8 5 Table of tightening torques Copyright 2020 ABB All rights reserved HZTL4032_EN Rev P March 2020 8 5 Table of tightening torques Fig 38 Overview of tightening torques 1 Only A155 M with uncoupled filter silencer Page 74 171 ...

Page 105: ... for the designated screw fittings Position Part number A150 A155 02 72051 M16 275 Nm M16 275 Nm 02a 72054 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 M16 200 Nm 20 81154 M6 10 Nm 21 81155 M8 55 Nm 22 81152 ...

Page 106: ...ghtening 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 39 Tightening torques for insulation 1 Tightening torque for attaching the insulation with integrated burst protection at the tur bine casing 2 Tightening torque for atta...

Page 107: ...ch 2020 9 Dismantling and fitting with removed air inlet and gas outlet 9 1 Removing air inlets Fig 40 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 8201...

Page 108: ...yright 2020 ABB All rights reserved HZTL4032_EN Rev P March 2020 A155 M Uncoupled filter silencer Fig 41 Removing the uncoupled filter silencer 1 Secure lifting gear to filter silencer 81000 2 Unscrew the hexagon head screws 72054 and remove along with Verbus Ripp wash ers 72053 and three safety plates 72055 3 Remove the filter silencer 81000 Page 78 171 ...

Page 109: ...the casing position for assembly Variant without support Fig 42 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 appropriat...

Page 110: ...served HZTL4032_EN Rev P March 2020 Variant with support Fig 43 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 80 171 ...

Page 111: ...e gas outlet casing Copyright 2020 ABB All rights reserved HZTL4032_EN Rev P March 2020 Fig 44 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 81 171 ...

Page 112: ...h 2020 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 pr...

Page 113: ...y for service work 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 45 Dismantling the gas outlet flange Product Press off screws strength 8 8 Tightening torque A150 3 x M16 x 30 150 Nm A155 3 x M16 x 40 150 Nm Table 40 3 press off screws 1 Evenly press off and remove the gas outlet flange 57...

Page 114: ...re that the gas outlet 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 46 Removing the gas outlet flange Product Press off screws strength 8 8 Tightening torque A150 6 x M12 x 30 65 Nm A155 6 x M12 x 30 150 Nm Table 41 6 press off screws not included in the ABB scope of ...

Page 115: ...ch 2020 9 4 Removing the cartridge group with compressor and turbine casing Fig 47 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 48 Remove insulation 2 Remove the compressor casing ins...

Page 116: ...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 50 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 swivel ...

Page 117: ...e casing position for assembly Fig 51 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 th...

Page 118: ...e diffuser and the wall insert Fig 52 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 Rem...

Page 119: ...ridge group u Mark the casing position for assembly Fig 53 Removing cartridge group 1 Product Position Tightening torque Nm A150 01 150 A155 01 150 Table 42 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 sup...

Page 120: ...dge 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 cartridge ...

Page 121: ...t 9 6 Removing the cartridge group Copyright 2020 ABB All rights reserved HZTL4032_EN Rev P March 2020 Fig 55 Removing 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 91 171 ...

Page 122: ...p on the service support Copyright 2020 ABB All rights reserved HZTL4032_EN Rev P March 2020 9 7 Installing the cartridge group on the service support Fig 56 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 92 171 ...

Page 123: ...ir inlet and gas outlet 9 8 Removing the nozzle ring Copyright 2020 ABB All rights reserved HZTL4032_EN Rev P March 2020 9 8 Removing the nozzle ring Fig 57 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 93 171 ...

Page 124: ...1 28 A155 M 0 12 0 22 0 79 1 40 Table 43 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 5 Me...

Page 125: ...ng operation it must be clamped between the heat shield 42400 and the turbine casing 51000 Fig 59 Nozzle ring compression PD 42001 Bearing casing 51000 Turbine casing 42400 Heat shield 56001 Nozzle ring Product Nozzle ring compression PD mm A150 M 0 17 0 17 A155 M 0 17 0 17 Table 44 Nozzle ring compression PD 1 Measure values A B and S on cleaned surfaces 2 Calculate compression PD u If the calcul...

Page 126: ...ed HZTL4032_EN Rev P March 2020 9 11 Installing nozzle ring Fig 60 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 96 171 ...

Page 127: ...12 Installing the cartridge group Copyright 2020 ABB All rights reserved HZTL4032_EN Rev P March 2020 9 12 Installing the cartridge group Fig 61 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 97 171 ...

Page 128: ...htening torque Nm A150 01 150 A155 01 150 Table 45 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 tou...

Page 129: ... cartridge group Product Size Tightening torque Nm A150 M16 175 A155 M16 175 Table 46 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 hexago...

Page 130: ... Fig 64 Fitting the wall insert and the diffuser Product Size Tightening torque Nm A150 M6 8 A155 M6 8 Table 47 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 cas...

Page 131: ...4032_EN Rev P March 2020 Installing the compressor casing Fig 65 Installing the compressor casing Product Size Tightening torque Nm A150 M16 275 A155 M18 370 Table 48 Tightening torque 72011 1 Fit 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 132: ...urning the cartridge group with compressor and turbine casing Fig 66 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 lifti...

Page 133: ...h 2020 9 15 Installing the gas outlet flange Fig 67 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 cle...

Page 134: ...er gauges 01 into the gap without clearance simultaneously at the top N1 and the bottom N2 2 Calculate clearance N and compare it with the permissible values in the table 3 Push the feeler gauges 01 into the gap without clearance simultaneously at the top R2 and the bottom R1 4 Calculate clearance R and compare it with the permissible values in the table CAUTION Clearances outside the tolerance Se...

Page 135: ...air inlet and gas outlet 9 17 Fitting the insulation Copyright 2020 ABB All rights reserved HZTL4032_EN Rev P March 2020 9 17 Fitting the insulation Fig 69 Fitting the insulation u Fit the insulation according to the illustration Observe tightening torques see Table of tightening torques 74 Page 105 171 ...

Page 136: ...ing 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 71 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 plug...

Page 137: ...200 A155 M16 200 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 Fit hexagon nuts 51009 Observe the tightening torque 6...

Page 138: ... with support 1 Product Size Tightening torque Nm A150 M16 200 A155 M16 200 Table 51 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 gas outlet casing 61001 Secure lifting gear to the swivel lift ing eye 4 Place gas outlet casing on the turbine casing 51000 Observe the mark...

Page 139: ...ev P March 2020 Fig 74 Installing 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 74 9 Fit gas outlet casing insulation see Table of tightening torques 74 10 If present Attach waste gate pipe Tighten in accordance with enginebuilder s specifica...

Page 140: ...g the air inlets Product Size Tightening torque Nm A150 M16 275 A155 M18 370 Table 52 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 h...

Page 141: ...0 A155 M Uncoupled filter silencer Fig 76 Installing the uncoupled filter silencer Product Size Tightening torque Nm A155 M16 275 Table 53 Tightening torque 72054 1 Secure lifting gear to filter silencer 81000 2 Install the filter silencer 81000 3 Fit the hexagon nuts 72054 together with Verbus Ripp washers 72053 and three new safety plates 72055 uniformly at 120 to one another Observe the tighten...

Page 142: ...ch 2020 10 Dismantling and fitting cartridge concept 10 1 Removing air inlets Fig 77 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 112 171 ...

Page 143: ...20 ABB All rights reserved HZTL4032_EN Rev P March 2020 A155 M Uncoupled filter silencer Fig 78 Removing the uncoupled filter silencer 1 Secure lifting gear to filter silencer 81000 2 Unscrew the hexagon head screws 72054 and remove along with Verbus Ripp wash ers 72053 and three safety plates 72055 3 Remove the filter silencer 81000 Page 113 171 ...

Page 144: ... Rev P March 2020 10 2 Removing the compressor casing u Mark the casing position for assembly Fig 79 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 114 171 ...

Page 145: ...h 2020 If the compressor casing cannot be loosened it can be pressed off against the turbine cas ing with the press off tool 90042 Fig 80 Pressing off compressor casing 1 Remove front turbine casing insulation 2 Press off compressor casing with press off tool 90042 Fig 81 Remove the diffuser 1 Remove and dispose of the O ring 42012 2 Set the compressor casing 72000 down on a suitable support Page ...

Page 146: ... and the wall insert Fig 82 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 di...

Page 147: ...mantling and fitting cartridge concept 10 3 Removing the cartridge group Copyright 2020 ABB All rights reserved HZTL4032_EN Rev P March 2020 10 3 Removing the cartridge group Removing the insulation Fig 83 Removing insulation sheets u Remove insulation sheets Page 117 171 ...

Page 148: ...hreaded rod value X 1 Apply two marking lines M to the left and right of the cartridge group and the bracket 2 Support and fix the turbine casing 3 Loosen the clamping nut 42201 see Loosening the clamping nut 12 4 Screw threaded rod 42191 up to value X at the hexagon 5 Lift the centering bush 42193 using the threaded rod 42191 and hold it firmly If the centering bush jams Remove the clamping nut a...

Page 149: ...L4032_EN Rev P March 2020 Fig 85 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 119 171 ...

Page 150: ...ht 2020 ABB All rights reserved HZTL4032_EN Rev P March 2020 Fig 86 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 120 171 ...

Page 151: ...ing cartridge concept 10 4 Removing the nozzle ring Copyright 2020 ABB All rights reserved HZTL4032_EN Rev P March 2020 10 4 Removing the nozzle ring Fig 87 S_05180 1 Pull out the nozzle ring 56001 with the two extraction devices 90070 2 Remove the lamellar sealing ring 56005 Page 121 171 ...

Page 152: ...5 M 0 12 0 22 0 79 1 40 Table 55 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 5 Measure cl...

Page 153: ...on it must be clamped between the heat shield 42400 and the turbine casing 51000 Fig 89 Nozzle ring compression PD 42001 Bearing casing 51000 Turbine casing 42400 Heat shield 56001 Nozzle ring Product Nozzle ring compression PD mm A150 M 0 17 0 17 A155 M 0 17 0 17 Table 56 Nozzle ring compression PD 1 Measure values A B and S on cleaned surfaces 2 Calculate compression PD u If the calculated value...

Page 154: ...2_EN Rev P March 2020 10 7 Installing nozzle ring Fig 90 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 124 171 ...

Page 155: ...ut 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 t...

Page 156: ...e the 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 value X if value X is ...

Page 157: ...itting the wall insert and the diffuser Product Size Tightening torque Nm A150 M6 8 A155 M6 8 Table 59 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...

Page 158: ...v P March 2020 Installing the compressor casing Fig 94 Installing the compressor casing Product Size Tightening torque Nm A150 M16 275 A155 M18 370 Table 60 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 128 ...

Page 159: ...clearances N and R 1 Push the feeler gauges 01 into the gap without clearance simultaneously at the top N1 and the bottom N2 2 Calculate clearance N and compare it with the permissible values in the table 3 Push the feeler gauges 01 into the gap without clearance simultaneously at the top R2 and the bottom R1 4 Calculate clearance R and compare it with the permissible values in the table CAUTION C...

Page 160: ...ridge concept 10 11 Fitting the insula tion Copyright 2020 ABB All rights reserved HZTL4032_EN Rev P March 2020 10 11 Fitting the insulation Fig 96 Fitting the insulation u Fit the insulation according to the illustration Observe tightening torques see Table of tightening torques 74 Page 130 171 ...

Page 161: ...r inlets Product Size Tightening torque Nm A150 M16 275 A155 M18 370 Table 62 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 h...

Page 162: ...Uncoupled filter silencer Fig 98 Installing the uncoupled filter silencer Product Size Tightening torque Nm A155 M16 275 Table 63 Tightening torque 72054 1 Secure lifting gear to filter silencer 81000 2 Install the filter silencer 81000 3 Fit the hexagon nuts 72054 together with Verbus Ripp washers 72053 and three new safety plates 72055 uniformly at 120 to one another Observe the tightening torqu...

Page 163: ...ial tool set 90160 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 See also chapter Tools 165 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 sc...

Page 164: ...ol not included in the ABB scope of delivery Fig 99 Customer tool Position Description Quantity 01 Collection tub 500x400x30mm 1 02 Torque spanner 40 200 Nm with plug connection for holding inser tion tools 14x18 mm 1 Table 64 Customer tool Customer tool not included in the ABB scope of delivery Fig 100 Customer tool Position Description Quantity 01 Universal pliers 1 Table 65 Customer tool Page 1...

Page 165: ...ing elements if they fall 2 Loosen the two nuts on one side by using 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 102 Removing the fastening strips 4 Remove the nuts 51007 with spanner h...

Page 166: ...antling and fitting special tools for fastening strips 11 1 Ap plication special tools Copyright 2020 ABB All rights reserved HZTL4032_EN Rev P March 2020 5 Loosen the nuts 51007 from the remaining fastening strips and remove the lugs 51002 with washers 51003 Page 136 171 ...

Page 167: ... 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 104 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 t...

Page 168: ...ls Copyright 2020 ABB All rights reserved HZTL4032_EN Rev P March 2020 Fig 105 Fitting the bottom fastening strip Product Size Tightening torque Nm A150 M M16 85 A155 M M16 70 Table 67 Tightening torque 51007 with spanner holder 5 Fit the nuts 51007 with spanner holder 90165 90166 and attached torque span ner 02 Observe the tightening torque Page 138 171 ...

Page 169: ...erved HZTL4032_EN Rev P March 2020 11 1 1 A155 M Fit fastening strips with extended special tool Fig 106 Fitting the cartridge group 1 Fit nuts 51007 of the upper fastening strips 51002 shown in the picture and tighten with the torque spanner 02 without a spanner holder Observe the tightening torque Product Size Tightening torque Nm A155 M16 175 Table 68 Tightening torque 51007 Page 139 171 ...

Page 170: ...mages so that all work steps are visually clear Fig 107 Positioning the fastening strip 2 Position fastening strip 51002 in the tool disassembly segment 90164 3 Clamp the lugs A of the tool disassembly segment slightly using the universal pliers 03 to fix the fastening strip 4 Position the fastening strip with the tool disassembly segment onto the set screws 5 Push the fastening strip with the too...

Page 171: ...ening strips 11 1 Ap plication special tools Copyright 2020 ABB All rights reserved HZTL4032_EN Rev P March 2020 Fig 108 Clamping piece 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 141 171 ...

Page 172: ...torque 51007 with spanner holder 10 Screw nut 51007 loosely to 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 to the set screw by pulling the cord 15 ...

Page 173: ...ing 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 110 Initial situation u Before disassembly mark the positions of the elbows 51311 Fig 111 Disassembly of the elbows 1 Just loosen the union nuts 51316 of the elbows 51311 Do not remove them yet 2 Just loosen the sc...

Page 174: ...ponent op tional 12 1 Disassembly Copyright 2020 ABB All rights reserved HZTL4032_EN Rev P March 2020 Fig 112 Disassembly of the elbows u Remove the elbows 51311 from the connecting pieces 51313 in the specified order 01 02 03 04 05 Fig 113 Pipe disassembly 1 Undo union nuts 51316 of pipe 51312 2 Remove pipe Page 144 171 ...

Page 175: ...0 Fig 114 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 115 Disassembly of the cleaning nozzle u Remove cleaning nozzles 51301 with screw 01 in accordance with the following table Product Thread Length mm Quantity A150 M M8 40 1 A155 M M10 50 1 Table 70 Dismantl...

Page 176: ... Table 71 Dismantling 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 117 Assembly of the connecting pieces 1 Posit...

Page 177: ...1 Coat 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 119 Elbow 1 assembly u Coat thread and contact surfaces of cutting ring with high temperature grease u Screw union nuts 51316 of elbows 51311 in the specified order 01 02 03 04 05 ...

Page 178: ...al 12 2 Assembly Copyright 2020 ABB All rights reserved HZTL4032_EN Rev P March 2020 Fig 120 Elbow 2 assembly Product 51314 Nm 51316 Nm A150 M 80 70 A155 M 100 90 Table 72 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 148 171 ...

Page 179: ...erved HZTL4032_EN Rev P March 2020 13 Fitting the cleaning nozzles with multi inlet turbine casings Fig 121 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 149 171 ...

Page 180: ...mentally 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 fec...

Page 181: ...tridge group Incorrect handling of a cartridge group can damage the turbocharger and cause injuries to persons u Have repairs to the cartridge group carried out by an ABB Turbocharging Service Station only To enable you to quickly put an engine back into operation after a turbocharger has sus tained damage ABB Turbocharging recommends having a replacement cartridge group available in storage The d...

Page 182: ...e 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 Fig 122 Fitting the 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 as...

Page 183: ...e is not included in the ABB scope of delivery and must be manufactured by the operating company according to the following drawing Material General structural steel in accordance with DIN EN 10025 2 Fig 123 Cover plate drawing Product B1 0 5 B2 B3 B4 0 2 B5 B6 0 1 B7 ØD1 0 2 ØD2 R1 M A150 138 9 135 240 21 4 2 0 320 71 4 413 6 33 196 M12 A155 164 6 160 286 5 25 5 2 0 385 84 6 492 39 232 M16 Table ...

Page 184: ...ut of operation at short notice 14 5 Cover plate drawing Copyright 2020 ABB All rights reserved HZTL4032_EN Rev P March 2020 Fig 124 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 74 Cover plate dimensions mm Page 154 171 ...

Page 185: ... 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 da...

Page 186: ...ring 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 attac...

Page 187: ...ggles 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 compon...

Page 188: ...l variants are not taken into account in this document contact an ABB Turbocharging Service Station u Dispose of placed and unusable parts in an environmentally friendly and professional 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 ...

Page 189: ...peration Manual 4 Product description A150 M56 66 57 67 A155 M 17 Spare parts 17 2 Required customer spare part set 97070 Copyright 2020 ABB All rights reserved HZTL4032_EN Rev P March 2020 Page 159 171 ...

Page 190: ...of turbocharger with part numbers Copyright 2020 ABB All rights reserved HZTL4032_EN Rev P March 2020 17 3 View of turbocharger with part numbers Fig 125 Overview of part numbers Depending on the specification of the turbocharger only available in customer spare part set 97070 Page 160 171 ...

Page 191: ...on 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 79000...

Page 192: ...rights reserved HZTL4032_EN Rev P March 2020 17 4 View of turbine cleaning device 17 4 1 One cleaning nozzle per turbine inlet Fig 126 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 162 171 ...

Page 193: ...0 17 4 2 6 nozzle turbine cleaning Fig 127 Overview of part numbers Part number Designation 51301 Cleaning nozzle 51302 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 Hexagon head screw 51316 Union nut 51317 Sealing stud Table 78 Spare parts list Page 163 171 ...

Page 194: ...5 Fig 128 Overview of part numbers Part number Designation 72052 Set screw 72053 Verbus Ripp washer 72054 Hexagon nut 72055 Safety plate 81000 Filter silencer 81145 Flange compressor end 81146 Flange turbine end 81147 Fixing ring 81148 Absorption element 81149 Mounting plate 81150 Fastening strips 81151 Roll pin 81152 Hexagon head screw 81153 Washer 81154 Socket screw 81155 Hexagon head screw Tabl...

Page 195: ...Socket screw 2 90042 Press off tool 2 90070 Extraction device 2 Table 80 Customer tool set 90000 ABB offers an optional special tool set 90160 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 Special tool 90160 Fig 129 Special tool Part nu...

Page 196: ...t number Description Quantity 90160 Special tool complete 1 90161 Bag 1 90162 Locking device 1 90163 Clamping piece 1 90164 Tool disassembly segment 1 90165 Spanner holder 2 Table 82 Special tool 90160 Tool sets can be ordered from any ABB Turbocharging Service Station The following spe cifications must be included in the order Turbocharger type Designation and part number of the tool set Page 166...

Page 197: ...ig 28 Soaking the turbine end 54 Fig 29 Disassembling the absorption element 57 Fig 30 Installing the absorption element 58 Fig 31 Swivel lifting eyes 67 Fig 32 Press off screws 68 Fig 33 Dismantling screw 68 Fig 34 Removing the cartridge group with com pressor and turbine casing 70 Fig 35 Cartridge concept 71 Fig 36 Optional spanner holder 72 Fig 37 Weights of assemblies 73 Fig 38 Overview of tig...

Page 198: ...2 119 Fig 86 Removing cartridge group 2 120 Fig 87 S_05180 121 Fig 88 Measuring clearance A and B 122 Fig 89 Nozzle ring compression PD 123 Fig 90 Installing the nozzle ring 124 Fig 91 Installing the cartridge group 1 125 Fig 92 Installing the cartridge group 2 126 Fig 93 Fitting the wall insert and the diffuser 127 Fig 94 Installing the compressor casing 128 Fig 95 Measuring clearances N and R 12...

Page 199: ...igures Copyright 2020 ABB All rights reserved HZTL4032_EN Revision P March 2020 Fig 126 Overview of part numbers 162 Fig 127 Overview of part numbers 163 Fig 128 Overview of part numbers 164 Fig 129 Special tool 165 Fig 130 Special tool 166 Page 169 171 Page 169 171 ...

Page 200: ... during operation Exhaust gas temperature too high 61 Table 24 Malfunctions during operation Charge air pressure too low 61 Table 25 Malfunctions during operation Charge air pressure too high 62 Table 26 Malfunctions during operation Engine performance losses 62 Table 27 Malfunction Turbocharger pumping 63 Table 28 Malfunction Sporadic surge blows 63 Table 29 Malfunctions when stopping Runout nois...

Page 201: ...le 65 Customer tool 134 Table 66 Tightening torque 51007 137 Table 67 Tightening torque 51007 with spanner holder 138 Table 68 Tightening torque 51007 139 Table 69 Tightening torque 51007 with spanner holder 142 Table 70 Dismantling screw 145 Table 71 Dismantling screw 146 Table 72 Tightening torque 51314 51316 148 Table 73 Cover plate dimensions mm 153 Table 74 Cover plate dimensions mm 154 Table...

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