ABB HT599244 Operation Manual Download Page 178

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Operation Manual / 4 Product description / A150-M58/68

Figures

HZTL4041_EN

Revision D

March 2020

Figures

Fig. 1: Layout and function of the turbocharger ...... 6

Fig. 2: Compressor wheel cooling ................................ 7

Fig. 3: Warning plate locations .................................... 8

Fig. 4: Locations of the rating plates ......................... 9

Fig. 5: Suspension of complete turbocharger unit. 10

Fig. 6: Turbine cleaning nozzle.................................... 11

Fig. 7: Removing the turbocharger ............................ 11

Fig. 8: Loosening the clamping nut ........................... 12

Fig. 9: Turbocharger centre of gravity ...................... 13

Fig. 10: Inserting the gasket........................................ 14

Fig. 11: Inserting the threaded rods........................... 15

Fig. 12: Placing the turbocharger on the bracket.... 15

Fig. 13: Preparing the clamping nut for the tighten-
ing procedure ................................................................ 16

Fig. 14: Tightening pressure screws.......................... 17

Fig. 15: Connecting the speed sensor ....................... 18

Fig. 16: Connecting the compressor cooling air in-
take .................................................................................. 18

Fig. 17: Attaching the support .................................... 18

Fig. 18: Oil orifice .......................................................... 20

Fig. 19: Layout and overview of speed measurement
system ............................................................................. 27

Fig. 20: Replacing the speed sensor......................... 29

Fig. 21: Noise insulation, bellows ............................... 31

Fig. 22: Carrying out wet cleaning of compressor.. 41

Fig. 23: Turbine cleaning devices .............................. 44

Fig. 24: Carrying out wet cleaning of turbines ....... 45

Fig. 25: Cleaning the filter silencer............................ 47

Fig. 26: Compressor casing........................................ 49

Fig. 27: Diffuser............................................................. 50

Fig. 28: Turbine end, non-rotating parts ................. 52

Fig. 29: Soaking the turbine end ............................... 54

Fig. 30: Swivel lifting eyes........................................... 65

Fig. 31: Press-off screws ............................................. 66

Fig. 32: Dismantling screw........................................... 66

Fig. 33: Removing the cartridge group with com-
pressor and turbine casing.......................................... 68

Fig. 34: Cartridge concept ........................................... 69

Fig. 35: Optional spanner holder ................................ 70

Fig. 36: Weights of assemblies .................................... 71

Fig. 37

Overview of tightening torques ..................... 72

Fig. 38: Tightening torques for insulation................ 73

Fig. 39: Removing the air inlets................................... 74

Fig. 40: Remove gas outlet casing without support ...
75

Fig. 41: Removing gas outlet casing with support 1....
76

Fig. 42: Removing gas outlet casing with support 1 ...
77

Fig. 43: Removing the gas outlet flange ................... 78

Fig. 44: Turbine cleaning nozzle ................................. 79

Fig. 45: Remove insulation........................................... 79

Fig. 46: Removing the cartridge group with com-
pressor and turbine casing.......................................... 80

Fig. 47: Set down the cartridge group with the com-
pressor and turbine casing.......................................... 80

Fig. 48: Removing the compressor casing ............... 81

Fig. 49: Removing cartridge group 1.......................... 82

Fig. 50: Removing cartridge group 2 ......................... 83

Fig. 51: Removing cartridge group 3.......................... 84

Fig. 52: Installing the cartridge group on the service
support ............................................................................ 85

Fig. 53: Removing the nozzle ring............................... 86

Fig. 54: Measuring clearance A and B ........................ 87

Fig. 55: Nozzle ring compression PD ......................... 88

Fig. 56: Installing the nozzle ring ................................ 89

Fig. 57: Lifting the cartridge group and rotating it by
90°..................................................................................... 90

Fig. 58: Turning the cartridge group ......................... 91

Fig. 59: Installing the cartridge group....................... 92

Fig. 60: Fitting the diffuser.......................................... 93

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Summary of Contents for HT599244

Page 1: ... Turbocharging Operation Manual A150 M68 HT599244 English Original Operation Manual Chapter Document ID 1 Introduction HZTL4005_EN_G 2 Safety HZTL4022_EN_E 3 Safety data sheet HT599244 4 Product description HZTL4041_EN_D ...

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

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

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

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

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

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

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

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

Page 10: ......

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

Page 12: ...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: ...ion Manual A150 M68 Safety data sheet Page 1 1 Safety data sheet Copyright 2020 ABB All rights reserved HT599244 November 2020 A150 M68 HT599244 A150 M68 HT599244 546 650 546 620 1005795361 1200 12 50 50 2020 ...

Page 30: ......

Page 31: ...supply 19 3 2 Inspection procedures 21 3 3 Commissioning after taking out of operation 23 4 Monitoring operation 24 4 1 Oil pressure oil temperature 24 4 2 Exhaust gas temperature before turbine 26 4 3 Turbocharger speed 27 5 Operation and service 30 5 1 Noise emission 30 5 2 Service work 32 5 3 Expected replacement intervals 35 5 4 Stopping the engine 37 6 Periodic maintenance work 38 6 1 Forewor...

Page 32: ...11 Installing nozzle ring 89 9 12 Installing the cartridge group 90 9 13 Installing the compressor casing 93 9 14 Turning the cartridge group with compressor and turbine casing 95 9 15 Installing the gas outlet flange 96 9 16 Radial clearances N and R 97 9 17 Fitting the insulation 98 9 18 Installing the cartridge group with compressor and turbine casing 99 9 19 Installing the gas outlet casing 10...

Page 33: ... 133 14 2 Installing the replacement turbocharger 134 14 3 Installing the replacement cartridge group 134 14 4 Fitting the cover plate 135 14 5 Cover plate drawing 136 15 Mothballing the turbocharger 138 15 1 Taking the engine out of operation for up to 12 months 138 15 2 Taking the engine out of operation for more than 12 months 139 16 Disposing of turbocharger components 140 17 Spare parts 141 1...

Page 34: ...f 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 possible 1 2...

Page 35: ...ved HZTL4041_EN Rev D 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 5 151 ...

Page 36: ...ABB All rights reserved HZTL4041_EN Rev D March 2020 1 4 Layout and function of the turbocharger Fig 1 Layout and function of the turbocharger 01 Filter silencer air suction branch 06 Gas outlet casing 02 Compressor casing 07 Turbine 03 Compressor wheel 08 Nozzle ring 04 Diffuser 09 Turbine casing 05 Bearing casing Page 6 151 ...

Page 37: ...directed to the engine cylinders The rotor runs in two radial plain bearings which are located between the compressor and the turbine in the bearing casing 05 The axial bearing is also in the form of a plain bearing 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 lies at the deepest point of t...

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

Page 39: ...ns of the rating plates Copyright 2020 ABB All rights reserved HZTL4041_EN Rev D 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 9 151 ...

Page 40: ... 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 Weigh...

Page 41: ...ction 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 connec...

Page 42: ...o 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 Working in a...

Page 43: ...ult 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 secure t...

Page 44: ... 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 42001 Bearing casing 01a Oil inlet possible variant 42200 O ring 01b Oil inlet possible variant 42195 O ring 02 Oil drain Detail A Screw plug with orifice hole option u Fit the gasket 42200 on the oil inlet screw plug 01a or 01b with...

Page 45: ...ds Fig 11 Inserting the threaded rods 1 Lightly oil the surfaces of the threaded rods 42091 2 Screw the threaded rods into the bracket and hand tighten 3 Check dimensions 2 3 3 Placing the turbocharger on the bracket Fig 12 Placing the turbocharger on the bracket u Make sure that covers of the oil and water connections are removed 1 Carefully lower the turbocharger 2 Check dimensions again Page 15...

Page 46: ...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 tightening...

Page 47: ...ontrolled 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 the table 5...

Page 48: ...sion 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 cooling...

Page 49: ... 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 Filtering th...

Page 50: ... in the bearing casing Fig 18 Oil orifice 01 Bearing casing 02 Screw plug left or right 03 Screw plug with orifice hole left or right see also Inserting gaskets 14 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 20 151 ...

Page 51: ...n 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 are pr...

Page 52: ...f 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 see chapter Eliminating malfunctions 57 Lubricants an...

Page 53: ...he gas inlet and the gas outlet 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 circulation to the turbocharger into operation u Prepare the turbocharger...

Page 54: ...ation 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 Table 4 L...

Page 55: ...not start engine before start preheat oil 30 C Table 5 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 table Th...

Page 56: ...placement 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 Operation ...

Page 57: ... 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 Tachometer Al...

Page 58: ...e 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 be con...

Page 59: ...ith a sealing lip and an O ring No additional gasket is required during assembly Fig 20 Replacing the speed sensor Part number A150 M58 68 86505 M12 x 1 5 15 Nm Table 7 Tightening torque 86505 u Reduce the engine performance to idling and then stop the engine Pay attention to post lubrication Stopping the engine 37 u Switch off the lubricating oil supply to the turbocharger u Disconnect cable conn...

Page 60: ...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 acoustically insu...

Page 61: ...opyright 2020 ABB All rights reserved HZTL4041_EN Rev D 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 31 151 ...

Page 62: ...t 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 service in...

Page 63: ... 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 operating...

Page 64: ...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 cooler...

Page 65: ...acing 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 Turbine cas...

Page 66: ...he 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 filtering oil ...

Page 67: ...pping it u Observe the oil pressure specified for engine idling see Table 4 Lubricating oil pressure at oil inlet before turbocharger 24 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 values post ...

Page 68: ...nsuring max imum fuel efficiency Maintenance inter val Maintenance work Operating status 24 72 h 1 Cleaning the compressor during operation 39 Engine load 50 85 50 200 h 1 Cleaning the turbine during operation 42 Engine load 20 40 guideline value According to rating plate 2 Cleaning components mechanically 46 Engine stopped Table 9 Maintenance table h Hours of operation 1 If the maintenance interv...

Page 69: ...ocharging 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 channels if ...

Page 70: ...erating 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 to pres...

Page 71: ...oved 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 10 Parameters for wet cleaning of compressor u Remove sealing plug 27005 u Fill container with 0 4 dm3 of pure water u Scr...

Page 72: ...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 combus...

Page 73: ...nded 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 before t...

Page 74: ...ion 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 11 Turbi...

Page 75: ... the 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 stab...

Page 76: ...ge 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 casings may have pro...

Page 77: ...r 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 Rinse in ...

Page 78: ...on 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 47 u Insert the absorption segments 81136 into the sheet metal coverings 81137 u Bend the sheet metal coverings 81137 back to...

Page 79: ...uipment PPE according to 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 casing 72000 Compressor casing u Clean the compres...

Page 80: ...ning In the case of slotted diffusers this applies in particular to the diffuser slots 03 and the dif fuser annulus 02 u Cleaning procedures should be selected that do not result in removal of the diffuser s base material or damage to its surfaces u The evenness of all surfaces 01 between the diffuser blades must be checked visually The surfaces must be flat and even Any deformations or deteriorat...

Page 81: ...terials 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 safety gogg...

Page 82: ...often 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 the info...

Page 83: ...ding 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 impair...

Page 84: ... turbine are described in the following Fig 29 Soaking the turbine end Product A mm B mm C mm A150 200 35 382 Table 14 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 Selection of the clea...

Page 85: ... 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 tract thi...

Page 86: ...s 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 wall ...

Page 87: ... Turbocharging Service Station Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Contact enginebuilder Table 16 Malfunctions when starting Vibrations Rubbing of rotating parts Normal behaviour not a malfunction Turbochar ger A slight amount of uniform wear at the circumference of the rotor components caused by slight local rubbing against adjacent components is permitted ...

Page 88: ...on Engine Oil filter heavily contaminated Clean Oil pump in lubricating system defect ive Check replace Manometer displays incorrectly Replace manometer Table 18 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 38 Rotor components or bearin...

Page 89: ... water too high Check clean cooling system Insufficient ventilation Improve ventilation Table 21 Malfunctions during operation Exhaust gas temperature too high Charge air pressure too low Engine performance and engine speed unchanged suction condition normal Possible causes Remedy Turbochar ger Manometer display not correct Replace manometer Supply pipe to manometer not sealed Repair leak Filter s...

Page 90: ...erely 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 38 Optimize o...

Page 91: ...e 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 38 Heavy contamination deposits in the turbine or in the nozzle ring Engine Protective grating...

Page 92: ... 27 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 ger Tur...

Page 93: ...chapter Ordering spare parts 141 Replacing the speed sensor 29 Table 29 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 noise ...

Page 94: ...ay 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 machine u ...

Page 95: ... Identification is guaranteed 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 ...

Page 96: ...ss off screws Product Thread Length Quantity A150 M58 68 M12 30 6 Table 33 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 32 Dismantling screw Product Thread Length mm Quantity A150 M58 68 M8 40 1 Table 34 Dismantling screw Page 66 151 ...

Page 97: ...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 specially c...

Page 98: ...ed 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 the al...

Page 99: ...roup 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 or suspe...

Page 100: ...smantling and fitting special tools for fastening strips 122 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...

Page 101: ...semblies are rounded up standard values Fig 36 Weights of assemblies Designation A150 M58 68 kg 01 Radial air suction branch 35 02 Filter silencer 120 03 Compressor casing with insulation 250 04 Diffuser 18 05 Cartridge group 270 06 Nozzle ring 8 07 Burst ring 11 08 Turbine casing 1 inlet 320 2 inlets 290 3 inlets 300 09 Gas outlet flange 35 10 Gas outlet casing with insulation 160 Table 35 Weight...

Page 102: ... of tightening torques Fig 37Overview of tightening torques The following tightening torques must be observed for the designated screw fittings Position Part number A150 M58 68 02 72051 M16 275 Nm 04 79041 M6 8 Nm 08 51007 M16 175 Nm 51007 with spanner holder 90165 M16 85 Nm 09 51009 M16 200 Nm 11 72011 M16 275 Nm 15 86505 M12 x 1 5 15 Nm 16a M16 200 Nm Table 36 Tightening torques Page 72 151 ...

Page 103: ...ABB All rights reserved HZTL4041_EN Rev D March 2020 Fig 38 Tightening torques for insulation The following tightening torques must be observed for the specified bolted connections Position Part number A150 M58 68 16a M16 200 Nm 16b M12 65 Nm 18 M6 10 Nm 19 M8 25 Nm 20 M10 45 Nm Table 37 Tightening torques for insulation Page 73 151 ...

Page 104: ...fitting with removed air inlet and gas outlet 9 1 Removing air inlets u Mark the casing position for assembly Fig 39 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...

Page 105: ...sing position for assembly Variant without support Fig 40 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 appropriate plac...

Page 106: ... HZTL4041_EN Rev D March 2020 Variant with support Fig 41 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 76 151 ...

Page 107: ...outlet casing Copyright 2020 ABB All rights reserved HZTL4041_EN Rev D March 2020 Fig 42 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 77 151 ...

Page 108: ... hammer ensure 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 43 Removing the gas outlet flange Product Press off screws to be used strength 8 8 Tightening torque A150 M58 68 6x M12 x 30 65 Nm Table 38 Press off screws gas outlet flange not included ...

Page 109: ... 9 4 Removing the cartridge group with compressor and turbine casing Fig 44 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 45 Remove insulation 2 Remove the compressor casing insulation...

Page 110: ...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 47 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 lifting...

Page 111: ... 01 Disc as scratch protection not included in the ABB scope of delivery If the compressor casing cannot be loosened it can be pressed off against the turbine cas ing with the press off tool 90042 90022 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 18...

Page 112: ...e group u Mark the casing position for assembly Fig 49 Removing cartridge group 1 Product Position Tightening torque Nm A150 M58 68 01 150 Table 39 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 113: ...oup 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 group ...

Page 114: ...Removing the cartridge group Copyright 2020 ABB All rights reserved HZTL4041_EN Rev D March 2020 Fig 51 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 84 151 ...

Page 115: ...he service support Copyright 2020 ABB All rights reserved HZTL4041_EN Rev D March 2020 9 7 Installing the cartridge group on the service support Fig 52 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 85 151 ...

Page 116: ...et and gas outlet 9 8 Removing the nozzle ring Copyright 2020 ABB All rights reserved HZTL4041_EN Rev D March 2020 9 8 Removing the nozzle ring Fig 53 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 86 151 ...

Page 117: ...0 22 0 80 1 39 Table 40 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 clearance B...

Page 118: ...g operation it must be clamped between the heat shield 42400 and the turbine casing 51000 Fig 55 Nozzle ring compression PD 42001 Bearing casing 51000 Turbine casing 42400 Heat shield 56001 Nozzle ring Product Nozzle ring compression PD mm A150 M58 68 0 17 0 17 Table 41 Nozzle ring compression PD 1 Measure values A B and S on cleaned surfaces 2 Calculate compression PD u If the calculated value PD...

Page 119: ...4041_EN Rev D March 2020 9 11 Installing nozzle ring Fig 56 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 89 151 ...

Page 120: ...talling the cartridge group Copyright 2020 ABB All rights reserved HZTL4041_EN Rev D March 2020 9 12 Installing the cartridge group Fig 57 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 90 151 ...

Page 121: ...ing torque Nm A150 M58 68 01 150 Table 42 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 122: ...rtridge group Product Size Tightening torque Nm A150 M58 68 M16 175 Table 43 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 nuts 51...

Page 123: ...D March 2020 9 13 Installing the compressor casing Fitting the diffuser Fig 60 Fitting the diffuser Product Size Tightening torque Nm A150 M58 68 M6 8 Table 44 Tightening torque 79041 1 Secure the diffuser 79000 with fixing discs 79040 and new screws 79041 Observe the tightening torque 2 Fit lifting gear with swivel lifting eye S to compressor casing 72000 and rotate the compressor casing by 180 P...

Page 124: ...1_EN Rev D March 2020 Installing the compressor casing Fig 61 Installing the compressor casing Product Size Tightening torque Nm A150 M58 68 M16 275 Table 45 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 Page 94 15...

Page 125: ... the cartridge group with compressor and turbine casing Fig 62 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 lifting gea...

Page 126: ... 9 15 Installing the gas outlet flange Fig 63 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 clearance...

Page 127: ... 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 Serious damage to e...

Page 128: ...let and gas outlet 9 17 Fitting the insulation Copyright 2020 ABB All rights reserved HZTL4041_EN Rev D March 2020 9 17 Fitting the insulation Fig 65 Fitting the insulation u Fit the insulation according to the illustration Observe tightening torques see Table of tightening torques 72 Page 98 151 ...

Page 129: ...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 67 Installing the cartridge group with compressor and turbine casing 3 Mount and tighten the clamping nut see Fastening the turbocharger with a clamping nut 16 4 Remove lifting gear from bearing casing 5 If present Remove the screw plug from ...

Page 130: ...16 200 Table 47 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 Fit insul...

Page 131: ...th support 1 Product Size Tightening torque Nm A150 M58 68 M16 200 Table 48 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 marking 5 Fit...

Page 132: ...arch 2020 Fig 70 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 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 specifica tions...

Page 133: ...e air inlets Product Size Tightening torque Nm A150 M58 68 M16 275 Table 49 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 hea...

Page 134: ... fitting cartridge concept 10 1 Removing air inlets u Mark the casing position for assembly Fig 72 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 Pa...

Page 135: ...March 2020 10 2 Removing the compressor casing u Mark the casing position for assembly Fig 73 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 105 151 ...

Page 136: ... press off tool 90042 90022 Fig 74 Pressing off compressor casing 01 Disc as scratch protection not included in the ABB scope of delivery 1 Remove front turbine casing insulation 2 Press off compressor casing with press off tool 90042 90022 and disk 01 Fig 75 Remove the diffuser 1 Remove and dispose of the O ring 42012 2 Set the compressor casing 72000 down on a suitable support 3 Loosen screws 79...

Page 137: ...fitting cartridge concept 10 3 Removing the cartridge group Copyright 2020 ABB All rights reserved HZTL4041_EN Rev D March 2020 10 3 Removing the cartridge group Removing the insulation Fig 76 Removing insulation sheets u Remove the insulation sheets 01 02 03 Page 107 151 ...

Page 138: ...020 Removing the cartridge group Fig 77 Removing cartridge group 1 1 Apply two marking lines M to the left and right of the cartridge group and the bracket 2 Support and fix turbine casing and gas outlet casing 3 Loosen the clamping nut 42201 see Loosening the clamping nut 12 4 Use the hexagon to raise the threaded rod 42191 up to its stop 5 Attach lifting gear to cartridge group Page 108 151 ...

Page 139: ...N Rev D March 2020 Fig 78 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 109 151 ...

Page 140: ...ight 2020 ABB All rights reserved HZTL4041_EN Rev D March 2020 Fig 79 Removing cartridge group 3 1 Unscrew the threaded stud 42191 downwards and remove the clamping nut 42201 2 Remove and dispose of the O rings 42195 42200 3 If present Remove the metal C ring 51105 4 Attach the cartridge group to the service support 90012 Page 110 151 ...

Page 141: ...tridge concept 10 4 Removing the nozzle ring Copyright 2020 ABB All rights reserved HZTL4041_EN Rev D March 2020 10 4 Removing the nozzle ring Fig 80 S_05180 1 Pull out the nozzle ring 56001 with the two extraction devices 90070 2 Remove the lamellar sealing ring 56005 Page 111 151 ...

Page 142: ... 1 39 Table 50 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 clearance B and comp...

Page 143: ...on it must be clamped between the heat shield 42400 and the turbine casing 51000 Fig 82 Nozzle ring compression PD 42001 Bearing casing 51000 Turbine casing 42400 Heat shield 56001 Nozzle ring Product Nozzle ring compression PD mm A150 M58 68 0 17 0 17 Table 51 Nozzle ring compression PD 1 Measure values A B and S on cleaned surfaces 2 Calculate compression PD u If the calculated value PD lies out...

Page 144: ...v D March 2020 10 7 Installing nozzle ring Fig 83 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 114 151 ...

Page 145: ... D March 2020 10 8 Installing the cartridge group Fig 84 Installing the cartridge group 1 Attach lifting gear to bearing casing 2 Remove the fixing screws and lift cartridge group out of the service support 90012 3 Screw the threaded stud 42191 into the clamping nut 42201 from below as far as its stop 4 Fit new O rings 42195 42200 5 If present Insert the metal C ring 51105 Page 115 151 ...

Page 146: ...51007 with a spanner holder see Special tools for fastening strips 122 Product Size Tightening torque Nm A150 M58 68 M16 85 Table 53 Tightening torque 51007 with spanner holder 1 Move the cartridge group into the turbine casing and align with the markings M made on the bracket at the time of disassembly 2 Use the hexagon to screw the threaded rod 42191 down to its stop 3 Tighten pressure screws of...

Page 147: ...h 2020 10 9 Installing the compressor casing Fitting the diffuser Fig 86 Fitting the diffuser Product Size Tightening torque Nm A150 M58 68 M6 8 Table 54 Tightening torque 79041 1 Secure the diffuser 79000 with fixing discs 79040 and new screws 79041 Observe the tightening torque 2 Fit lifting gear with swivel lifting eye S to compressor casing 72000 and rotate the compressor casing Page 117 151 ...

Page 148: ...March 2020 Installing the compressor casing Fig 87 Installing the compressor casing Product Size Tightening torque Nm A150 M58 68 M16 275 Table 55 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 118 151 ...

Page 149: ... 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 Clearances outside ...

Page 150: ...concept 10 11 Fitting the insula tion Copyright 2020 ABB All rights reserved HZTL4041_EN Rev D March 2020 10 11 Fitting the insulation Fig 89 Fitting the insulation u Fit the insulation according to the illustration Observe tightening torques see Table of tightening torques 72 Page 120 151 ...

Page 151: ...lets Product Size Tightening torque Nm A150 M58 68 M16 275 Table 57 Tightening torque 72051 1 Attach lifting gear to the filter silencer 81000 or air suction branch 82000 2 Fit a new O ring 81010 to the filter silencer 81000 or a new O ring 82010 to the air suction branch 82000 3 Install the filter silencer 81000 or air suction branch 82000 4 Fit the fastening strips 72012 with hexagon head screws...

Page 152: ...f tightening torques for the strip connection between the cartridge group and the turbine casing See also chapter Tools 146 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 nuts on the turbocharger should not be tightened with this tool Customer tool not included in the ABB scope of delivery Fig ...

Page 153: ...ments 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 93 Removing the fastening strips 4 Remove the nuts 51007 with spanner holder 90...

Page 154: ...itting the upper fastening strips Product Size Tightening torque Nm A150 M58 68 M16 175 Table 59 Tightening torque 51007 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 Fig 95 Fitting the bottom fastening strip 2 Position the collection tray 01 to catch any fixing elements if the...

Page 155: ... group is fitted at this point in time In order to provide a clear representation of the work step the cartridge group is not illustrated in work step 5 Fig 96 Fitting the bottom fastening strip Product Size Tightening torque Nm A150 M58 68 M16 85 Table 60 Tightening torque 51007 with spanner holder 5 Fit the nuts 51007 with spanner holder 90165 90166 and attached torque span ner 02 Observe the ti...

Page 156: ... 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 97 Initial situation u Before disassembly mark the positions of the elbows 51311 Fig 98 Disassembly of the elbows 1 Just loosen the union nuts 51316 of the elbows 51311 Do not remove them yet 2 Just loosen the screws 51...

Page 157: ... op tional 12 1 Disassembly Copyright 2020 ABB All rights reserved HZTL4041_EN Rev D March 2020 Fig 99 Disassembly of the elbows u Remove the elbows 51311 from the connecting pieces 51313 in the specified order 01 02 03 04 05 Fig 100 Pipe disassembly 1 Undo union nuts 51316 of pipe 51312 2 Remove pipe Page 127 151 ...

Page 158: ... Fig 101 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 102 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 M58 68 M8 40 1 Table 61 Dismantling screw Pa...

Page 159: ...smantling 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 104 Assembly of the connecting pieces 1 Position gaskets ...

Page 160: ...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 106 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 to the ...

Page 161: ... 12 2 Assembly Copyright 2020 ABB All rights reserved HZTL4041_EN Rev D March 2020 Fig 107 Elbow 2 assembly Product 51314 Nm 51316 Nm A150 M58 68 80 70 Table 63 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 131 151 ...

Page 162: ...ZTL4041_EN Rev D March 2020 13 Fitting the cleaning nozzles with multi inlet turbine casings Fig 108 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 132 151 ...

Page 163: ...y 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 fect then ...

Page 164: ... 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 defecti...

Page 165: ...owing 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 109 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 assembly...

Page 166: ...awing The cover plate 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 110 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 Table 64 Cover plate dimensions mm Page ...

Page 167: ...king out of operation at short notice 14 5 Cover plate drawing Copyright 2020 ABB All rights reserved HZTL4041_EN Rev D March 2020 Fig 111 Dimensions for cover plate Product A B D1 D2 0 1 A150 90 10 90 0 2 28 2 Table 65 Cover plate dimensions mm Page 137 151 ...

Page 168: ...aring parts are largely protected against corrosion Preparations for mothballing WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or con tact with them may be harmful to health u Do not breathe in these substances and avoid contact with the skin u Ensure proper ventilation u Observe the information in the material safety data shee...

Page 169: ...rts are dismantled by an ABB Turbocharging Service Station and stored separately The turbocharger is completely removed either as a whole unit or in individual parts For the measures always necessary for preparing the turbocharger parts for mothballing see section Taking the engine out of operation for up to 12 months subsection Preparations for mothballing If the turbocharger remains attached to ...

Page 170: ...ear 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 components of...

Page 171: ...del 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 spar...

Page 172: ...bocharger with part numbers Copyright 2020 ABB All rights reserved HZTL4041_EN Rev D March 2020 17 3 View of turbocharger with part numbers Fig 112 Overview of part numbers Depending on the specification of the turbocharger only available in customer spare part set 97070 Page 142 151 ...

Page 173: ...01 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 61100 Gas outlet casing insulation 61140 Insulation transition piece 61301 Support 72000 Compressor casing 72011 Hexagon head screw 72012 Fastening strip 72060 Hood 72061 Insulating bush 79000 Diffuser 79040 Fixing disc 79041 in ...

Page 174: ... reserved HZTL4041_EN Rev D March 2020 17 4 View of turbine cleaning device 17 4 1 One cleaning nozzle per turbine inlet Fig 113 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 68 Spare parts list Page 144 151 ...

Page 175: ... 2 6 nozzle turbine cleaning Fig 114 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 69 Spare parts list Page 145 151 ...

Page 176: ... screw 2 90042 Press off tool 2 90070 Extraction device 2 Table 70 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 115 Special tool Part number D...

Page 177: ...right 2020 ABB All rights reserved HZTL4041_EN Rev D March 2020 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 147 151 ...

Page 178: ...8 Turbine end non rotating parts 52 Fig 29 Soaking the turbine end 54 Fig 30 Swivel lifting eyes 65 Fig 31 Press off screws 66 Fig 32 Dismantling screw 66 Fig 33 Removing the cartridge group with com pressor and turbine casing 68 Fig 34 Cartridge concept 69 Fig 35 Optional spanner holder 70 Fig 36 Weights of assemblies 71 Fig 37Overview of tightening torques 72 Fig 38 Tightening torques for insula...

Page 179: ...le ring compression PD 113 Fig 83 Installing the nozzle ring 114 Fig 84 Installing the cartridge group 115 Fig 85 Installing the cartridge group 2 116 Fig 86 Fitting the diffuser 117 Fig 87 Installing the compressor casing 118 Fig 88 Measuring clearances N and R 119 Fig 89 Fitting the insulation 120 Fig 90 Installing the air inlets 121 Fig 91 Customer tool 122 Fig 92 Positioning the collection tub...

Page 180: ... Charge air pressure too low 59 Table 23 Malfunctions during operation Charge air pressure too high 60 Table 24 Malfunctions during operation Engine performance losses 60 Table 25 Malfunction Turbocharger pumping 61 Table 26 Malfunction Sporadic surge blows 61 Table 27 Malfunctions when stopping Runout noises 62 Table 28 Malfunctions when stopping Runout time too short 62 Table 29 Malfunction of t...

Page 181: ...tening torque 51007 124 Table 60 Tightening torque 51007 with spanner holder 125 Table 61 Dismantling screw 128 Table 62 Dismantling screw 129 Table 63 Tightening torque 51314 51316 131 Table 64 Cover plate dimensions mm 136 Table 65 Cover plate dimensions mm 137 Table 66 Customer spare part set 97070 141 Table 67 Spare parts list 143 Table 68 Spare parts list 144 Table 69 Spare parts list 145 Tab...

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ABB HT599244, Operation Manual

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