ABB HT603060 Operation Manual Download Page 2

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Summary of Contents for HT603060

Page 1: ...on Serial number HT603060 Customer part number A155MDD003B1 Delivery date yyyy mm dd 2021 05 20 Weight 1800 kg Operating limits according to rating plate Speed limit in test rig operation only nMmax 448 1 s Speed limit during operation nBmax 434 1 s Gas inlet temperature limit in test rig operation only tMmax 630 C Gas inlet temperature limit during operation tBmax 600 C ...

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Page 3: ...e 15 2 6 Warning plates on the turbocharger 16 2 7 Turbocharger rating plate 17 2 8 Periodic check of the pressure vessels 19 2 9 Lifting of loads 20 2 10 Prerequisites for operation and maintenance 21 2 11 Hazards during operation and maintenance 22 2 12 Safe operation 24 2 13 Safe maintenance 25 3 Removing and Installing 29 3 1 Turbocharger weight and transportation 29 3 2 Removing the turbochar...

Page 4: ... 9 5 Table of tightening torques 93 10 Dismantling and fitting with removed air inlet and gas outlet 95 10 1 Removing air inlets 95 10 2 Removing the gas outlet casing 97 10 3 Removing the gas outlet flange 100 10 4 Removing the cartridge group with compressor and turbine casing 103 10 5 Removing the compressor casing 105 10 6 Removing the cartridge group 107 10 7 Installing the cartridge group on...

Page 5: ...ning strips 150 12 1 Application special tools 151 13 Removing and installing 6 nozzle turbine cleaning component optional 158 13 1 Disassembly 158 13 2 Assembly 161 14 Fitting the cleaning nozzles with multi inlet turbine casings 164 15 Taking out of operation at short notice 165 15 1 Possible emergency repairs 165 15 2 Installing the replacement turbocharger 166 15 3 Installing the replacement c...

Page 6: ...nual explains the turbocharger and contains instructions for safe opera tion The Operation Manual is a complement to and expansion of existing national regulations for occupational safety accident prevention and environmental protection Target group The Operation Manual is aimed at engineers and trained mechanics responsible for the proper operation of the engine and for the turbocharger connected...

Page 7: ... abb com turbocharging 1 3 Essential information Design variants This document is valid for different design variants of turbochargers There may be sections and descriptions 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 turbocharg...

Page 8: ...yout and function of the turbocharger Fig 2 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 6 194 ...

Page 9: ...ine 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 deepest poi...

Page 10: ...which facilitates 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 in this document Offic...

Page 11: ...ram Pictogram 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 ...

Page 12: ... VCI WARNING Health protection when handling VCI VCI products are not hazardous in terms of the Ordinance on Hazardous Substances Nevertheless the following points must be observed when handling VCI u Observe information in material safety data sheet u Ensure proper space ventilation u Do not eat drink or store food at the workplace while working with VCI u Clean hands and face after working with ...

Page 13: ...his case 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 component Replace the desiccant agent Re...

Page 14: ...1 Introduction 1 7 Registered trademarks Copyright 2021 ABB All rights reserved HZTL4032_EN Rev Q January 2021 1 7 Registered trademarks The trademarks of outside companies are used in this document These are marked with the symbol Page 12 194 ...

Page 15: ...terials are a consequence 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 ...

Page 16: ...espiratory mask to protect against Dusts Gases Safety helmet Ear protection Table 3 Personal protective equipment to be worn specific to the respective task 2 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 ev...

Page 17: ...d 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 intended uses 1 Euromot The European Association of Internal C...

Page 18: ...rning plates on the turbocharger Warning plates are affixed at the following locations Fig 6 Warning plate locations If warning 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 plat...

Page 19: ... 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 i...

Page 20: ...ded replacement intervals In such cases we recommend contacting the nearest ABB Turbochar ging Service Station nMmax tMmax normally apply only when running at overload 110 during trials on the engine test bed These limit values can also be permitted during operation for special applications Operation above nMmax and tMmax is not permitted Non observance of the recommended inspection and replacemen...

Page 21: ...els The locally applicable legal regulations regarding periodic checks of the pressure vessels must be observed The operating company is responsible for the safe operation of the pressure vessel WARNING Danger due to pressure vessels The operating company must make sure the pressure vessels are in proper working condition and monitor them Necessary repair or maintenance work must be performed prom...

Page 22: ...against mechanical hazards Wear safety helmet Fig 9 Attachment of loads on the crane hook Fig 10 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 descri...

Page 23: ...he Operation Manual must be checked 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 prerequisit...

Page 24: ...lways 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 WARNING Danger...

Page 25: ...for providing protection against contact with hot surfaces u Compliance with the instructions and specifications given by the en ginebuilder to protect against hot turbocharger surfaces is compulsory Wear safety gloves to protect against thermal hazards Hazards due to rotating parts WARNING Hazards due to rotating parts Contact with rotating parts can cause severe injury The turbocharger is never ...

Page 26: ...cles and objects littering the workplace u Check all pipes to and from the turbocharger for damage and leaks before commission ing u Check turbocharger for recognisable damage or defects every 12 hours of operation or at least once a day u Report any damage and any alterations of operational characteristics to the responsible department immediately u In case of damage take the turbocharger out of ...

Page 27: ...erform operations for which you have received instruction or train ing Wear safety footwear to protect against mechanical hazard and risk of fall ing Wear protective clothing WARNING Risk of falling When working on the turbocharger there is a risk of falling 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 pla...

Page 28: ...erved u Observe the material safety data sheet for the cleaning agent or solvent u Wear personal protective equipment PPE according to the material safety data sheet u Inspect the electric cables for abrasion and damage before and after your cleaning work Safety during disassembly assembly maintenance and repair u Observe the procedures for set up service and inspection work and the inspection int...

Page 29: ...perations for which you have previously received instruc tion or training Hazards due to operating materials and supplies Operating materials and supplies are substances required for the operation of the 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 opera...

Page 30: ...on 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 c...

Page 31: ...installing and transport ing the turbocharger The weight specified below applies to the heaviest variant possible Depending on the specification the weight specified on the rating plate may be lower than the standard value specified here Fig 11 Suspension of complete turbocharger unit A Complete turbocharger unit without gas outlet casing B Complete turbocharger unit with gas outlet casing Product...

Page 32: ...on 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 13 Removing the turbocharger u Secure the lifting gear to the turbocharger see illustration u If present Loosen and remove the compressor wheel cooling connecti...

Page 33: ...t 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 14 Loosening the clamping nut 1 Working in a ci...

Page 34: ...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 15 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 the ...

Page 35: ...January 2021 3 3 Installing the turbocharger 3 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 16 Inserting the gasket 01 Oil supply 02 Oil drain 42200 O ring 42201 Bearing casing 42202 O ring Page 33 194 ...

Page 36: ...ace 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 in the brac...

Page 37: ...sing 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 must be loos...

Page 38: ... 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 19 Preparing the clamping nut for the tightening pro...

Page 39: ...ntrolled 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 40: ... 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 22 Connecting the compressor cooling air intake u Remove the screw plug on the connection for the compressor wheel cooling 06 ...

Page 41: ...pecifications regarding the selection of lubricating oil and the oil change intervals 4 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 4 1 3 Oil filtering Filtering the lu...

Page 42: ...Rev Q January 2021 4 1 5 Oil orifice in the bearing casing Fig 24 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 40 194 ...

Page 43: ...e 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 presen...

Page 44: ...4 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 see chapter...

Page 45: ...ling 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 circulation to...

Page 46: ...n 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 7 Lubri...

Page 47: ... start engine before start preheat oil 30 C Table 8 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 The s...

Page 48: ...ement 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 Manu...

Page 49: ...ed 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 5 3 2 Layout and overview Fig 25 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 Altern...

Page 50: ...opped 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 contact...

Page 51: ...ng lip and an O ring No additional gasket is required during assembly Fig 26 Replacing the speed sensor Part number A150 A155 86505 M12 x 1 5 15 Nm M12 x 1 5 15 Nm Table 10 Tightening torque 86505 u Reduce the engine performance to idling and then stop the engine Pay attention to post lubrication Stopping the engine 57 u Switch off the lubricating oil supply to the turbocharger u Disconnect cable ...

Page 52: ...tance 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 insulat...

Page 53: ...ht 2021 ABB All rights reserved HZTL4032_EN Rev Q January 2021 Suggestion for noise insulation bellows Fig 27 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 51 194 ...

Page 54: ... 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 interv...

Page 55: ...rs after commissioning u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en gine is stopped 6 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 6 2 4 Service work according to data on the rating plate Usually after 8000 16000 operating hou...

Page 56: ... 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 Ex...

Page 57: ...g 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 casing ...

Page 58: ...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 con...

Page 59: ...ng it u Observe the oil pressure specified for engine idling see Table 7 Lubricating oil pressure at oil inlet before turbocharger 44 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 lub...

Page 60: ...um fuel efficiency Maintenance inter val Maintenance work Operating status 24 72 h 1 Cleaning the compressor during operation 59 Engine load 50 85 50 200 h 1 Cleaning the turbine during operation 62 Engine load 20 40 guideline value According to rating plate 2 Cleaning components mechanically 66 Engine stopped 12000 h Uncoupled filter silencer A155 M Changing the absorption element 76 Engine stopp...

Page 61: ...arging 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 sal...

Page 62: ...ting periods in the lower range of performance that both turbocharger compressors are cleaned 7 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 pressur...

Page 63: ...d by the mechanical action of the impacting droplets 7 2 5 Carrying out wet cleaning of the compressor Fig 28 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 13 Parameters for wet cleaning of compressor u Remove sealing plug 27005 u Fill container with 0 4 dm3 of pure water u Screw ...

Page 64: ...se 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 ti...

Page 65: ...d This cleaning process is faster and reduces the risk of surging of the tur bocharger 7 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 the ...

Page 66: ...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 14 Turbine w...

Page 67: ...emperature at the turbine inlet is not exceeded during cleaning Fig 30 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 stabilisation phas...

Page 68: ...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 casings may h...

Page 69: ...ing 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 col...

Page 70: ...egments 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 31 Cleaning the filter silencer 67 u Insert the absorption segments 81136 into the sheet metal coverings 81137 u Bend the sheet metal coverings 81137 back to the...

Page 71: ...al 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 32 Compressor end non rotating parts 72000 Compressor casing 77000 Wall insert 79000 Diffuser u Cle...

Page 72: ...als 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 goggles ...

Page 73: ...n 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 informat...

Page 74: ...g to the following description 7 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 th...

Page 75: ...e described in the following Fig 34 Soaking the turbine end Product A mm B mm C mm A150 200 35 382 A155 240 40 454 Table 17 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...

Page 76: ...d 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 this c...

Page 77: ...ad 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 to t...

Page 78: ...48 in uncoupled filter silencers must be replaced every 12000 hours of operation Disassembling the absorption element Fig 35 Disassembling the absorption element 1 Remove the filter silencer see Fig 47 Removing the uncoupled filter silencer 96 2 Dismantle the hexagon head screws 81152 with washers 81153 and mounting plate 81149 3 Remove the socket screws 81154 roll pins 81151 flanges 81145 81146 a...

Page 79: ...ement 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 81152 Observ...

Page 80: ...rbocharging Service Station Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Contact enginebuilder Table 20 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 Thi...

Page 81: ...ngine Oil filter heavily contaminated Clean Oil pump in lubricating system defect ive Check replace Manometer displays incorrectly Replace manometer Table 22 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 58 Rotor components or bearing da...

Page 82: ...er too high Check clean cooling system Insufficient ventilation Improve ventilation Table 25 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 silen...

Page 83: ...ly 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 58 Optimize oil ...

Page 84: ...use 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 58 Heavy contamination deposits in the turbine or in the nozzle ring Engine Protective grating in ...

Page 85: ...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 Turboch...

Page 86: ...ter Ordering spare parts 173 Replacing the speed sensor 49 Table 33 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 com ...

Page 87: ...ave 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 ABB ...

Page 88: ...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 37 Swivel lifting e...

Page 89: ...t Thread Length Quantity A150 M12 30 mm 3 or 6 A155 M16 30 mm 3 or 6 Table 37 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 39 Dismantling screw Product Thread Length mm Quantity A150 M M8 40 1 A155 M M10 50 1 Table 38 Dismantling screw Page 87 194...

Page 90: ...oads 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 const...

Page 91: ...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 alter...

Page 92: ...p 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 suspensi...

Page 93: ...tling and fitting special tools for fastening strips 150 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 sho...

Page 94: ...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 39 Weights of assemblies i...

Page 95: ...e following tightening torques must be observed 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 N...

Page 96: ...orques 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 41 Tightening torques for insulation 1 Tightening torque for attaching the insulation with integrated burst protection at the tur bine casing 2 Tightening torque for attaching the ...

Page 97: ... Dismantling and fitting with removed air inlet and gas outlet 10 1 Removing air inlets Fig 46 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 9...

Page 98: ... ABB All rights reserved HZTL4032_EN Rev Q January 2021 A155 M Uncoupled filter silencer Fig 47 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 96 194 ...

Page 99: ...ng position for assembly Variant without support Fig 48 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 place ...

Page 100: ...4032_EN Rev Q January 2021 Variant with support Fig 49 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 98 194 ...

Page 101: ...t casing Copyright 2021 ABB All rights reserved HZTL4032_EN Rev Q January 2021 Fig 50 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 99 194 ...

Page 102: ...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 press off s...

Page 103: ...vice 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 51 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 42 3 press off screws 1 Evenly press off and remove the gas outlet flange 57002 with ...

Page 104: ...e 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 52 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 43 6 press off screws not included in the ABB scope of delivery 1...

Page 105: ... 4 Removing the cartridge group with compressor and turbine casing Fig 53 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 54 Remove insulation 2 Remove the compressor casing insulation 3...

Page 106: ...ed 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 31 Fig 56 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 ey...

Page 107: ...position for assembly Fig 57 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 the compres...

Page 108: ... and the wall insert Fig 58 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 109: ...up u Mark the casing position for assembly Fig 59 Removing cartridge group 1 Product Position Tightening torque Nm A150 01 150 A155 01 150 Table 44 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 110: ... 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 ver...

Page 111: ...ing the cartridge group Copyright 2021 ABB All rights reserved HZTL4032_EN Rev Q January 2021 Fig 61 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 109 194 ...

Page 112: ...vice support Copyright 2021 ABB All rights reserved HZTL4032_EN Rev Q January 2021 10 7 Installing the cartridge group on the service support Fig 62 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 110 194 ...

Page 113: ...gas outlet 10 8 Removing the nozzle ring Copyright 2021 ABB All rights reserved HZTL4032_EN Rev Q January 2021 10 8 Removing the nozzle ring Fig 63 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 111 194 ...

Page 114: ... M 0 12 0 22 0 79 1 40 Table 45 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 cle...

Page 115: ...ion it must be clamped between the heat shield 42400 and the turbine casing 51000 Fig 65 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 46 Nozzle ring compression PD 1 Measure values A B and S on cleaned surfaces 2 Calculate compression PD u If the calculated valu...

Page 116: ...EN Rev Q January 2021 10 11 Installing nozzle ring Fig 66 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 114 194 ...

Page 117: ...g the cartridge group Copyright 2021 ABB All rights reserved HZTL4032_EN Rev Q January 2021 10 12 Installing the cartridge group Fig 67 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 115 194 ...

Page 118: ...orque Nm A150 01 150 A155 01 150 Table 47 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 119: ...e group Product Size Tightening torque Nm A150 M16 175 A155 M16 175 Table 48 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 120: ...Fitting the wall insert and the diffuser Product Size Tightening torque Nm A150 M6 8 A155 M6 8 Table 49 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 Fi...

Page 121: ... Q January 2021 Installing the compressor casing Fig 71 Installing the compressor casing Product Size Tightening torque Nm A150 M16 275 A155 M18 370 Table 50 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 119 1...

Page 122: ...e cartridge group with compressor and turbine casing Fig 72 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 gear 3...

Page 123: ... 15 Installing the gas outlet flange Fig 73 Installing the gas outlet flange 1 If present Insert the metal C ring 57003 into the turbine casing 51000 and secure with high vacuum grease 2 Fit swivel lifting eye S to the gas outlet flange 57002 Secure lifting gear to the swivel lifting eye 3 Install gas outlet flange in turbine casing 51000 4 Measure radial clearance R see chapter Radial clearances ...

Page 124: ... 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 Serious dam...

Page 125: ...d gas outlet 10 17 Fitting the insulation Copyright 2021 ABB All rights reserved HZTL4032_EN Rev Q January 2021 10 17 Fitting the insulation Fig 75 Fitting the insulation u Fit the insulation according to the illustration Observe tightening torques see Table of tightening torques 93 Page 123 194 ...

Page 126: ...t 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 77 Installing the cartridge group with compressor and turbine casing 3 Mount and tighten the clamping nut see Fastening the turbocharger with a clamping nut 36 4 Remove lifting gear from bearing casing 5 If present Remove the screw plug from th...

Page 127: ...M16 200 Table 52 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 insu...

Page 128: ...port 1 Product Size Tightening torque Nm A150 M16 200 A155 M16 200 Table 53 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 129: ...y 2021 Fig 80 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 93 9 Fit gas outlet casing insulation see Table of tightening torques 93 10 If present Attach waste gate pipe Tighten in accordance with enginebuilder s specifica tions Pa...

Page 130: ... inlets Product Size Tightening torque Nm A150 M16 275 A155 M18 370 Table 54 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 he...

Page 131: ...Uncoupled filter silencer Fig 82 Installing the uncoupled filter silencer Product Size Tightening torque Nm A155 M16 275 Table 55 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 132: ... Dismantling and fitting cartridge concept 11 1 Removing air inlets Fig 83 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 130 194 ...

Page 133: ...ights reserved HZTL4032_EN Rev Q January 2021 A155 M Uncoupled filter silencer Fig 84 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 131 194 ...

Page 134: ...ry 2021 11 2 Removing the compressor casing u Mark the casing position for assembly Fig 85 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 132 194 ...

Page 135: ... the compressor casing cannot be loosened it can be pressed off against the turbine cas ing with the press off tool 90042 Fig 86 Pressing off compressor casing 1 Remove front turbine casing insulation 2 Press off compressor casing with press off tool 90042 Fig 87 Remove the diffuser 1 Remove and dispose of the O ring 42012 2 Set the compressor casing 72000 down on a suitable support Page 133 194 ...

Page 136: ...wall insert Fig 88 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 dispose of ...

Page 137: ...mm A155 M 144 2 mm Table 56 Threaded 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 31 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 j...

Page 138: ... Q January 2021 Fig 91 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 136 194 ...

Page 139: ... All rights reserved HZTL4032_EN Rev Q January 2021 Fig 92 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 137 194 ...

Page 140: ...e concept 11 4 Removing the nozzle ring Copyright 2021 ABB All rights reserved HZTL4032_EN Rev Q January 2021 11 4 Removing the nozzle ring Fig 93 S_05180 1 Pull out the nozzle ring 56001 with the two extraction devices 90070 2 Remove the lamellar sealing ring 56005 Page 138 194 ...

Page 141: ... 22 0 79 1 40 Table 57 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 142: ... be clamped between the heat shield 42400 and the turbine casing 51000 Fig 95 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 58 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 o...

Page 143: ...anuary 2021 11 7 Installing nozzle ring Fig 96 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 141 194 ...

Page 144: ...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 threaded ro...

Page 145: ... 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 not reache...

Page 146: ... wall insert and the diffuser Product Size Tightening torque Nm A150 M6 8 A155 M6 8 Table 61 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 the diffu...

Page 147: ...021 Installing the compressor casing Fig 100 Installing the compressor casing Product Size Tightening torque Nm A150 M16 275 A155 M18 370 Table 62 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 145 194 ...

Page 148: ... 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 Clearances ...

Page 149: ...t 11 11 Fitting the insula tion Copyright 2021 ABB All rights reserved HZTL4032_EN Rev Q January 2021 11 11 Fitting the insulation Fig 102 Fitting the insulation u Fit the insulation according to the illustration Observe tightening torques see Table of tightening torques 93 Page 147 194 ...

Page 150: ...roduct Size Tightening torque Nm A150 M16 275 A155 M18 370 Table 64 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 151: ...ilter silencer Fig 104 Installing the uncoupled filter silencer Product Size Tightening torque Nm A155 M16 275 Table 65 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 torque Page 149...

Page 152: ... turbine casing See also chapter Tools 188 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 105 Customer tool Position Description Quantity 01 Collection tub 500x400x30mm 1 ...

Page 153: ...ts 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 108 Removing the fastening strips 4 Remove the nuts 51007 with spanner holder 9016...

Page 154: ...g the fastening strips Fig 109 Fitting the upper fastening strips Product Size Tightening torque Nm A150 M16 175 A155 M16 175 Table 68 Tightening torque 51007 1 Fit the nuts 51007 of the upper fastening strips 51002 illustrated and tighten with a torque spanner 02 without a spanner holder Observe the tightening torque Fig 110 Fitting the bottom fastening strip 2 Position the collection tub 01 to c...

Page 155: ...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 5 Fig 111 Fitting the bottom fastening strip Product Size Tightening torque Nm A150 M M16 85 A155 M M16 70 Table 69 Tightening torque 51007 with spanner holder 5 Fit the nuts 51007 with spanner holder 90165 90166 and attached...

Page 156: ...32_EN Rev Q January 2021 12 1 1 A155 M Fit fastening strips with extended special tool Fig 112 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 70 Tightening torque 51007 Page 154 194 ...

Page 157: ...hat all work steps are visually clear Fig 113 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 tool disassem...

Page 158: ... 12 1 Ap plication special tools Copyright 2021 ABB All rights reserved HZTL4032_EN Rev Q January 2021 Fig 114 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 156 194 ...

Page 159: ...07 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 Fit nuts 5...

Page 160: ...le turbine cleaning component optional 13 1 Disassembly The following illustration shows the initial situation before the 6 nozzle turbine cleaning component is dismantled Fig 116 Initial situation u Before disassembly mark the positions of the elbows 51311 Fig 117 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 51314...

Page 161: ...onal 13 1 Disassembly Copyright 2021 ABB All rights reserved HZTL4032_EN Rev Q January 2021 Fig 118 Disassembly of the elbows u Remove the elbows 51311 from the connecting pieces 51313 in the specified order 01 02 03 04 05 Fig 119 Pipe disassembly 1 Undo union nuts 51316 of pipe 51312 2 Remove pipe Page 159 194 ...

Page 162: ...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 121 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 72 Dismantling screw ...

Page 163: ...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 123 Assembly of the connecting pieces 1 Position gasket...

Page 164: ...ead 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 125 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 con...

Page 165: ...mbly Copyright 2021 ABB All rights reserved HZTL4032_EN Rev Q January 2021 Fig 126 Elbow 2 assembly Product 51314 Nm 51316 Nm A150 M 80 70 A155 M 100 90 Table 74 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 163 194 ...

Page 166: ...32_EN Rev Q January 2021 14 Fitting the cleaning nozzles with multi inlet turbine casings Fig 127 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 164 194 ...

Page 167: ...ompatible 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 the...

Page 168: ...up 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 defective c...

Page 169: ...g 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 128 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 3 C...

Page 170: ...ncluded 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 129 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 75 Cover p...

Page 171: ...ion at short notice 15 5 Cover plate drawing Copyright 2021 ABB All rights reserved HZTL4032_EN Rev Q January 2021 Fig 130 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 76 Cover plate dimensions mm Page 169 194 ...

Page 172: ...ng 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 sheet f...

Page 173: ... 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 the...

Page 174: ...iratory 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 felt and ...

Page 175: ...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 18 2 Required customer spare part set 97070 For ...

Page 176: ...oil cooled 42167 42172 42170 42200 42172 42196 42195 42196 42197 42166 10900 42202 42193 42012 42194 42191 42047 42190 42201 42189 42188 Available within the spare part set if provided HZTL443471 Mod A A150 M58 68 only Part no Designation 10900 Cartridge 42012 O ring 42047 Screw plug 42166 Screw 42167 Cover 42170 Insulation 42172 Hexagon head screw 42188 Hexagon head screw 42189 Gasket 42190 Expan...

Page 177: ...Illustrations Copyright 2021 ABB All rights reserved HZTL4032_EN Rev Q January 2021 Part no Designation 42194 Gasket 42195 O ring 42196 Orifice oil inlet 42197 Safety ring 42200 O ring 42201 Clamping nut 42202 Screw plug Table 78 Spare parts Cartridge oil cooled Page 175 194 ...

Page 178: ...20 42305 42301 42019 42008 42302 42303 p pre assembled Available within the spare part set HZTL443310 Mod C A150 M58 68 only Part no Designation 42001 Bearing casing 42005 p Sealing bush 42006 p Spring type pin 42008 Socket screw 42019 Hexagon head screw 42020 Washer 42301 Bearing cover 42302 Piston ring 42303 Piston ring 42305 O ring 42306 O ring 42308 O ring 42400 Heat shield Table 79 Spare part...

Page 179: ... spare part set if provided HZTL443470 Mod A A150 M58 68 only Part no Designation 21000 Turbine 21002 Piston ring 21006 Piston ring 21011 Sealing bush for shaft 25000 Compressor wheel 32101 Radial bearing 32102 Radial bearing 32103 Thrust ring 32104 Thrust bearing 32109 Sealing disc 32110 Bearing flange 32111 Auxiliary bearing 32112 Bearing flange 32113 Socket screw 32114 Socket screw 32159 Socket...

Page 180: ...W03 51107 TW04 51101 TW03 if provided HZTL443311 Mod B Part no Designation 51000 Turbine casing 51002 Fastening strip 51003 Verbusripp washer 51006 Stud 51008 Stud 51009 Hexagon nut 51010 o Insulation TW03 TW04 51027 Screw plug 51101 Hexagon head screw 51102 Tension washer 51105 o Metal C ring 51106 Hexagon head screw 51107 o Tension washer 51500 Burst protection 56001 Nozzle ring 56005 Lamellar s...

Page 181: ...W03 51106 TW04 51101 TW03 if provided HZTL443472 Mod A Part no Designation 51000 Turbine casing 51002 Fastening strip 51003 Verbusripp washer 51006 Stud 51007 Hexagon nut 51008 Stud 51009 Hexagon nut 51010 Insulation 51027 Screw plug 51101 Hexagon head screw 51102 Tension washer 51105 Metal C ring 51106 Hexagon head screw 51107 Tension washer 51500 Burst protection 56001 Nozzle ring 56005 Lamellar...

Page 182: ...TW04 51102 TW03 51106 TW04 51101 TW03 if provided HZTL443473 Mod A Part no Designation 51000 Turbine casing 51002 Fastening strip 51003 Verbusripp washer 51006 Stud 51008 Stud 51009 Hexagon nut 51010 Insulation 51027 Screw plug 51102 Tension washer 51105 Metal C ring 51106 Hexagon head screw 51107 Tension washer 51302 Gasket 51303 Screw plug 51500 Burst protection 56001 Nozzle ring 56005 Lamellar ...

Page 183: ...51317 51302 51303 51313 51309 51312 51314 51305 51308 51304 51310 HZTL443336 Mod B RT01 RT03 RT05 RT07 Part no Designation 51301 Cleaning nozzle 51302 Gasket 51303 Screw plug 51304 Flange 51305 Union branch 51308 Stud 51309 Expansion sleeve 51310 Hexagon nut 51311 Pipe elbow 51312 Pipe 51313 Joining piece 51314 Hexagon head screw 51316 Cap nut 51317 Stop plug Table 84 Spare parts Cleaning device P...

Page 184: ... 61100 61140 61202 61201 61005 p 61001 61301 61002 Available within the spare part set p pre assembled if provided HZTL443312 Mod C Part no Designation 61001 Gas outlet casing 61002 Gasket 61005 p Screw plug 61100 Insulation gas outlet casing GW03 61140 Insulation 61201 Hexagon head screw 61202 Tension washer 61301 Support Table 85 Spare parts Gas outlet casing radial Page 182 194 ...

Page 185: ...72006 p Available within the spare part set p pre assembled HZTL443313 Mod C A150 M58 68 only Part no Designation 72000 Compressor casing 72005 p Screw plug 72006 p Gasket 72011 Hexagon head screw 72012 Fastening strip 72016 Fastening strip 72060 Insulation 72061 Insulation sleeve 72062 Hexagon head screw 72063 Tension washer 77000 Wall insert 77005 O ring 77006 Stud 79000 Diffuser 79040 Fixing wa...

Page 186: ...within the spare part set if provided HZTL443314 Mod B A155 M Decoupled filter silencer only Part no Designation 72052 Hexagon socket set screw 72053 Verbusripp locking disc 72054 Hexagon nut 72055 Fuse 81000 Filter silencer complete 81005 Screw plug 81006 Gasket 81010 O ring 81135 Silencer body 81136 Absorption segment 81137 Cover sheet metal 81145 Flange compressor end 81146 Flange turbine end 8...

Page 187: ...agon head screw 81170 Screw plug 81171 Gasket 81265 Filter ring 81266 Cover grid 81271 Lock Table 87 Spare parts Filter silencer Air suction branch axial 82010 82000 82008 82007 82006 82005 Available within the spare part set HZTL443474 Mod A Part no Designation 82000 Air suction branch 82005 Screw plug 82006 Gasket 82007 Screw plug 82008 Gasket 82010 O ring Table 88 Spare parts Air suction branch...

Page 188: ...d HZTL4032_EN Rev Q January 2021 Air suction branch radial 82010 82000 82006 82008 82007 82005 Available within the spare part set HZTL443315 Mod B Part no Designation 82000 Air suction branch 82005 Screw plug 82006 Gasket 82007 Screw plug 82008 Gasket 82010 O ring Table 89 Spare parts Air suction branch radial Page 186 194 ...

Page 189: ...t 2021 ABB All rights reserved HZTL4032_EN Rev Q January 2021 Speed measurement system 86258 86526 86505 86515 if provided HZTL443475 Mod A Part no Designation 86258 Tachometer 86505 Speed sensor 86515 Cable connector 86526 F I Converter Table 90 Spare parts Speed measurement system Page 187 194 ...

Page 190: ...ew 2 90042 Press off tool 2 90070 Extraction device 2 Table 91 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 131 Special tool Part number Descr...

Page 191: ...escription 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 93 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 189 194 ...

Page 192: ...ompressor 61 Fig 29 Turbine cleaning devices 64 Fig 30 Carrying out wet cleaning of turbines 65 Fig 31 Cleaning the filter silencer 67 Fig 32 Compressor end non rotating parts 69 Fig 33 Turbine end non rotating parts 71 Fig 34 Soaking the turbine end 73 Fig 35 Disassembling the absorption element 76 Fig 36 Installing the absorption element 77 Fig 37 Swivel lifting eyes 86 Fig 38 Press off screws 8...

Page 193: ...ff compressor casing 133 Fig 87 Remove the diffuser 133 Fig 88 Dismantling the diffuser and the wall insert 134 Fig 89 Removing insulation sheets 135 Fig 90 Removing cartridge group 1 135 Fig 91 Removing cartridge group 2 136 Fig 92 Removing cartridge group 2 137 Fig 93 S_05180 138 Fig 94 Measuring clearance A and B 139 Fig 95 Nozzle ring compression PD 140 Fig 96 Installing the nozzle ring 141 Fi...

Page 194: ...ed HZTL4032_EN Revision Q January 2021 Fig 126 Elbow 2 assembly 163 Fig 127 Fit the cleaning nozzles 164 Fig 128 Fitting the cover plate 167 Fig 129 Cover plate drawing 168 Fig 130 Dimensions for cover plate 169 Fig 131 Special tool 188 Fig 132 Special tool 189 Page 192 194 Page 192 194 ...

Page 195: ...nctions during operation Speed re duces 79 Table 24 Malfunctions during operation Speed in creases 79 Table 25 Malfunctions during operation Exhaust gas temperature too high 80 Table 26 Malfunctions during operation Charge air pressure too low 80 Table 27 Malfunctions during operation Charge air pressure too high 81 Table 28 Malfunctions during operation Engine performance losses 81 Table 29 Malfu...

Page 196: ...holder 157 Table 72 Dismantling screw 160 Table 73 Dismantling screw 161 Table 74 Tightening torque 51314 51316 163 Table 75 Cover plate dimensions mm 168 Table 76 Cover plate dimensions mm 169 Table 77 Customer spare part set 97070 173 Table 78 Spare parts Cartridge oil cooled 175 Table 79 Spare parts Bearing casing oil cooled 176 Table 80 Spare parts Rotor and bearing parts 177 Table 81 Spare pa...

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ABB HT603060, Operation Manual

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